Ayush Singh

30000 MTPA Production of Methanol using H2/CO2 as
feedstock
PROJECT REPORT
Submission in the partial fulfilment of the
requirements for the award of the degree
of
BACHELOR OF TECHNOLOGY
in
CHEMICAL ENGINEERING
By
AYUSH SINGH
(Enrolment No. 18118018)
DEPARTMENT OF CHEMICAL ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
ROORKEE – 247667 (INDIA)
APRIL 2022
30000 MTPA Production of Methanol using H2/CO2 as feedstock
1. General
DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 1|Page

CERTIFICATE
This is to certify that the project report titled “30000 MTPA Production of Methanol using
H2/CO2 as feedstock”, which is being submitted by Mr. Ayush Singh in partial fulfilment of
the requirements for the award of degree of Bachelor of Technology in Chemical Engineering
at Indian Institute of Technology is a record of his own work carried out by him under my
supervision and guidance.
Place: Roorkee (Dr. Taraknath Das)
Dated: April 16, 2022 Assistant Professor
Department of Chemical Engineering
IIT Roorkee
Roorkee – 247667


ACKNOWLEDGEMENT
I express my sincere gratitude to everyone who has helped me complete this project. Firstly, I
would like to thank my parents, who have been constant moral support through thick and
thin. I feel immense pleasure and privilege to express my deep sense of indebtedness and
thankfulness towards our supervisor, Dr. Taraknath Das, for motivating us with constant
appreciation and appraisal.
I express sincere thanks to Dr. Vimal Kumar and Dr. Ashish Yadav for coordinating this
project throughout the year. I would also thank my Institution and the entire staff of Central
Library, IIT Roorkee, who provided me with facilities for various books and research papers.
I shall remain ever grateful to all the people, who have helped, inspired, and encouraged me
and, above all, made me an ever more learned person. Last but not least, I would like to
convey thanks to our friends and fellow mates who have directly or indirectly helped me in
the compilation of this report.
Ayush Singh
Enrollment No. 18118018
Group 1
B. Tech. IV Year
Department of Chemical Engineering
Indian Institute of Technology Roorkee


Table of Contents
1. General……………………………………………………………………………………………………………………………….1
2. Summary ......................................................................................................................... 10
2.1 Process Summary ........................................................................................................... 10

2.2 Organizational Structure ................................................................................................ 10
2.3 Utility Usage .................................................................................................................. 11
2.4 Cost and Profit Information ........................................................................................... 11
3. Project details .................................................................................................................. 12
3.1 Introduction .................................................................................................................... 12

3.2 Project Description ......................................................................................................... 12
3.2.1 Uses and present status of product/importance of the problem ............................... 13
3.2.2 Process Selection ..................................................................................................... 17
3.2.2.1 Available processes for the production of the product .................................... 17
3.2.2.2 Techno-economic appraisal of alternative processes/schemes ........................ 21
3.2.2.3 Status of technologies/schemes available ........................................................ 22
3.2.2.4 Selection of technology/schemes ..................................................................... 23
3.2.2.5 Source of knowhow of selected process/technology ....................................... 24
3.2.3 Raw Materials .......................................................................................................... 25

3.2.3.1 Detailed Specifications .................................................................................... 25
3.2.3.2 Requirement of raw materials .......................................................................... 29
3.2.3.3 Availability: Indigenous/Imported ................................................................... 29
3.2.3.4 Government policies for import of raw material ............................................. 32
3.2.3.5 Prevailing Prices .............................................................................................. 34
3.2.3.6 Testing procedures for the raw materials: ........................................................ 34
3.3 Material and Energy Flow Information .......................................................................... 34

3.4 Detailed Design of Equipment ....................................................................................... 49
3.4.1 Process design of all major equipment .................................................................... 49
3.4.2 Mechanical Design of equipment ............................................................................ 70
3.4.3 Drawing of Equipment ............................................................................................ 83
3.4.4 Specifications and material of construction of all process equipment .................... 85

3.4.5 Major engineering problems and their remedies ..................................................... 88

3.5 Materials Storage & Handling Facilities ........................................................................ 92
3.6 Process Instrumentation & Control and Safety Aspects .............................................. 105
4. Environmental Protection & Energy Conservation .......................................................... 121
4.1 Environmental Aspect .................................................................................................. 121

4.1.1 Air Pollution .......................................................................................................... 121
4.1.2 Liquid Effluents ..................................................................................................... 126
4.1.3 Solids Disposal ...................................................................................................... 131
4.1.4 Noise Pollution ...................................................................................................... 134
4.2 Energy Conservation .................................................................................................... 136
5. Plant Utilities ................................................................................................................. 139
5.1 Air System .................................................................................................................... 140

5.2 Heat Transfer Media..................................................................................................... 141
5.3 Water ............................................................................................................................ 144
5.4 Refrigeration System .................................................................................................... 146
5.5 Electricity ..................................................................................................................... 147
6. Organizational Structure and Manpower Requirement .................................................. 148
6.1 Organizational Structure .............................................................................................. 148

6.2 Manpower Requirement ............................................................................................... 154
7 Market prospects ........................................................................................................... 156
7.1 Brief Analysis of Demand and Supply Of methanol.................................................... 156

7.2 Present Production Capacity and Export Potential ...................................................... 159
7.3 Marketing set-up and Area of Consumption ................................................................ 162
8. Site Selection and Plant layout ....................................................................................... 164
9. Economic Evaluation & Profitability of the Project ......................................................... 172
10. References .................................................................................................................. 182



2. Summary
2.1 Process Summary
The project report attempts to make the techno-economic evaluation to produce 30000 MTPA
Methanol through Carbon dioxide and Hydrogen via an industrially feasible process with a
relatively low cost.
There are various methods of producing Methanol, and out of those, hydrogenation of Carbon
dioxide is selected as the desired route of production. The proposed location of the plant in
Kutch, Gujarat.
2.2 Organizational Structure
Figure 2.1 Organizational Chart
Total skilled employees: 80
Total unskilled employees: 100
Total organization cost per month: ₹ 95 lakhs (approximately).
Total organization cost per annum: ₹ 11.4 crores (approximately)
DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 10 | P a g e

2.3 Utility Usage

Table 2.1 Utility Usage
Utility Consumption Coefficient (Per MT Unit Rate In Cost (per MT of

of Output) INR Output)
Steam 4.5 1300 5850
Power 1200 5.75 6900
Water 0.11 30 3.3
Water 2000
Disposal
2.4 Cost and Profit Information

Table 2.2 Profitability analysis
Total Fixed Capital 322385148 INR
Total Working Capital 64477029 INR
Total Manufacturing Cost 449718370 INR

(Including overheads)
Market value of Finished Products (Rs/Kg) 40 INR
Annual revenue Through Sales 1200000000 INR
Gross Profit 500749400 INR
Assuming Tax Percent 45
Net Profit 275412170 INR
Payback Period 1.10 Years
Rate of Return 39.3 %
A minimum rate of 39.3 % is assured
The Payback period is 1.10 years which is an acceptable payback period.

3. Project details
3.1 Introduction
Methanol, also known as methyl alcohol or methyl hydrate, amongst other names, is a
chemical and the simplest alcohol, with the formula CH3OH (a methyl group linked to a
hydroxyl group, often abbreviated MeOH). It is a light, volatile, colourless, flammable liquid
with a strong alcoholic odour similar to ethanol (potable alcohol). Methanol is now primarily
generated in the industrial sector via the hydrogenation of carbon monoxide.
Figure 3.1: Methanol Structure
The project is about producing Methanol through Carbon dioxide and Hydrogen via an
industrially feasible process with a relatively low cost. As there are various processes
available to produce the product, the selection is based on the availability and cost of raw
materials. Methanol has widespread use, and trends show that it will increase further, and that
is why it is essential to study its technology schemes.
3.2 Project Description

3.2.1 Uses and present status of product/importance of the problem
Significant applications of methanol are listed below:

Table 3.1: Uses of Methanol
Category Category Description
As solvent Methanol is primarily used as an industrial solvent to help create

inks, resins, adhesives, and dyes. It is also used as a solvent in
manufacturing important pharmaceutical ingredients and products
such as cholesterol, streptomycin, vitamins, and hormones. In
methanol extract, you need a lower temperature to evaporate the
solvent in the rotary vapour, so the extract is less damaged than the
ethanol one. Ethanol and methanol contain both polar and non-polar
groups, which make them able
to extract both polar and non-polar compounds.
Formaldehyde, Methanol is primarily converted to Formaldehyde, which is widely

acetic acid, methyl used in many areas, especially polymers. The conversion entails
tert-butyl ether oxidation:
2CH₃OH +O₂ → 2CH₂O +2H₂0

Acetic acid can be produced from methanol. Methanol and
isobutene are combined to give methyl tert-butyl ether. Methyl tert-
butyl ether is a significant octane booster in gasoline
Methanol to Condensation of methanol to produce hydrocarbons and even

hydrocarbons, aromatic systems is the basis of several technologies related to gas
olefins, gasoline to liquids. These include methanol-to-hydrocarbon, methanol to
gasoline, methanol to olefins, and methanol to propylene. These
conversions are catalysed by zeolites as heterogeneous catalysts.
The methanol to gasoline process was once commercialized at
Motunui in New Zealand
The European Fuel Quality Directive permits fuel manufacturers to

Gasoline additive
add up to 3% methanol to gasoline supplied in Europe, along with

an equivalent quantity of cosolvent. China utilises around 4.5 billion

litres of methanol as a transportation fuel each year, in low-level
mixes for conventional cars and high-level blends in vehicles built
to run on methanol.
Others Methanol is the precursor to most simple methylamines, methyl

halides, and methyl ethers. Methyl esters are produced from
methanol, including the transesterification of fats and biodiesel
production via transesterification.
Properties of Methanol
Table 3.2: Properties of Methanol
Property Value
Molecular Weight (g) 32.01
Melting Point (°C) -97.6
Boiling Point (°C) 64.7
Density at 20°C (g/L) 998.2
Vapor Density (air = 1) 1.11
Critical Temperature (°C) 239
Critical Pressure (MPa) 8.084
Surface Tension at 20°C 22.50
Dielectric Constant at 25°C 32.70
Heat of Combustion (kJ/mol) 726.1
Heat of Fusion (kJ/mol) 3.17
Freezing point (⁰C) -97.6

Critical Density (g cm⁻3) 0.2715
Latent heat of vaporization (kJ/M) 37.43
Flash Point (°C) 9
Auto Ignition Temperature (°C) 470
Refractive index at 20°C 1.3321
Vapour Pressure at 20°C (mm of Hg) 96
Viscosity Liquid
At 0°C 0.793
At 25°C 0.544
At (-25) °C 1.258
Solubility Miscible in all proportions with water
Importance of the problem:
Carbon dioxide is a waste product from many industries which drastically harms the
environment and contributes to global warming and air pollution. Conversion of this harmful
gas to a useful product, i.e., Methanol by hydrogenation, has endless potential. As discussed
above, methanol is used in various industries as a raw product and is currently produced by
Natural Gas which required extreme reaction conditions. If we use Carbon dioxide instead of
natural gas, we will move towards a sustainable future with less carbon footprint. Also,
methanol produced with carbon dioxide has less impurities compared with Natural gas
method.
PRESENT STATUS OF PRODUCT:
Over 90 methanol plants worldwide have a combined production capacity of about 110
million Metric tons (almost 36.6 billion gallons or 138 billion litres). According to the
consulting firm HIS, Global methanol demand reached 70 million metric tons in 2015,
primarily driven by emerging energy Applications for methanol, which now account for over
40% of methanol consumption. Its energy use applications are driving demand growth for

methanol.
Figure 3.2: Methanol Market
Methanol demand is growing at a robust 6 to 8 % annually. The world has installed a capacity
of 120 MT of methanol and will be about 200 MT by 2025. Currently, Methanol accounts for
almost 9% of transport fuel in China. They have converted millions of vehicles running on
Methanol.
In 2017, 57% of global demand for methanol came from China, with other parts of the Asia-
pacific Accounting for 16%, Europe 15%, North America 9% and Latin America 3%.
Consumption of Methanol in India
Table 3.3: Methanol Consumption in India
Production Consumption Year Growth Rate

Year
Million tonnes (%)
2008-2009 0.2371 1.2927 16.59
2009-2010 0.3308 1.1071 -14.35
2010-2011 0.3745 1.1443 3.36
2011-2012 0.3599 1.4391 25.76
2012-2013 0.2549 1.4692 2.09
2013-2014 0.3072 1.5357 4.53

2014-2015 0.2098 1.8019 17.33
Figure 3.3: Methanol Demand
3.2.2 Process Selection

3.2.2.1 Available processes for the production of the product
This section discusses the methods which are used for the production of methanol.
(i) Production of Methanol by Hydrogenation of CO2
This process involves the hydrogenation of Carbon dioxide over a Copper based catalyst to
yield Methanol directly. It is an exothermic reaction that is favoured by low temperature and
high pressure. Although, a reaction temperature higher than 240 °C is considered to facilitate
the activation of CO2 molecules because of its thermodynamic stability and chemical
inertness.
The main products of CO2 hydrogenation over Cu based catalysts are methanol, water and
CO.

CO2 + 3H2 → CH3OH + H2O ΔH0298K = − 90.6 kJ/mol
If the temperature is increased further reverse water gas reaction occurs, which is not
desirable as it reduces the selectivity of methanol.
CO2 + H2 → CO + H2O ΔH0298K = +41.2 kJ/mol
Catalyst:
There are numerous Copper-based catalysts available for the hydrogenation of CO2 to
Methanol
and after studying the Selectivity, Yield, Conversion and reaction conditions of these
catalysts. We have decided to use Cu-Zr-Ce (35− 19.7–45.3) catalyst. The below table has
alternate catalysts which were considered during this research.
Table 3.4: Catalyst properties
Catalyst T(°C) P(MPa) Conv. (%) Sel. (%) Yield (%)
CuO/Ce0.4Zr0.6O2 280 3 13.2 71.8 9.5
Cu/plate ZnO/Al2O3 270 4.5 10.8 72.7
Cu/Zn/Ga/hydrophobic SiO2 270 2 5.6 99.5
LaCr0.5Cu0.5O3 250 2 10.4 90.8 9.4
CuO-ZnO/CeO2 (42− 14–44) 240 3 7.2 80 5.7
Cu-Zr-Ce (35− 19.7–45.3) 240 3 9.2 93.9 8.63
Process Conditions:
Temperature: 220°C to 280°C
Pressure: 3 MPa
In terms of reactant ratio, for H2/CO2 higher than the stoichiometric value, methanol
selectivity is promoted while the formation of by-products (CO and H2O) is inhibited.

(ii) Methanol production from natural gas
Today, methanol is manufactured using a proven technology predominantly based on natural

gas, with a small portion of the world capacity being based on petroleum fractions and
process off-gases. The basic concept, when using natural gas as the feedstock, comprises the
following process steps
1) Desulphurization of natural gas
2) Synthesis gas generation
3) Synthesis gas compression
4) Methanol synthesis
5) Methanol distillation
Figure 3.4: Methanol production from natural gas
Basic steps of methanol production
The most suitable choice, and therefore the plant layout, is determined by the customer’s
requirements and local conditions. Furthermore, high-pressure steam (HPS) and medium
pressure steam (MPS) are often generated by cooling the high-temperature synthesis gas and
the methanol synthesis reactor, respectively. The main reactions for methanol production are:
CO + 2H2 → CH3OH -91 kJ/mol
CO2 + 3H2 → CH3OH + H2O -49 kJ/mol
Therefore, the following ratio is ideal for methanol production:
(H2 - CO2) / (CO + CO2) = 2

The synthesis of carbon oxides to methanol is based on CuO/ZnO based catalysts, e.g.
Synetix catalysts. This catalyst type has proved its performance in adiabatic as well as in
isothermal reactors. The conversion of carbon oxides to methanol is an exothermic process at
high pressures and low temperatures. The synthesis unit operates at 40 - 110 bar and around
200 to 300 °C. The aim is to achieve a relatively high carbon efficiency to minimize the
amount of synthesis gas to be processed.
Figure 3.5: Methanol production from natural gas
(iii) Methanol production from Biosynthesis
Enzymes such as methane monooxygenases are involved in the catalytic conversion of

methane to methanol. These enzymes are mixed-function oxygenases, which means they
oxygenate while also producing water and NAD+.
CH4+O2+NADPH+H⁺→CH3OH+H2O+NAD⁺

Both Fe- and Cu-dependent enzymes have been characterised. Intense but largely fruitless
efforts have been undertaken to emulate this reactivity. Methanol is more easily oxidized than
is the feedstock methane, so the reactions tend not to be selective. Some strategies exist to
circumvent this problem.
These systems do not necessarily mimic the mechanisms employed by metalloenzymes but
draw some inspiration from them. Active sites can vary substantially from those known in the
enzymes. For example, a dinuclear active site is proposed in the sMMO enzyme, whereas a
mononuclear iron (alpha-oxygen) is proposed in the Fe-zeolite.
Biosynthesis of methanol from methane by Methylosinus trichosporium OB3b
Methylosinus trichosporium OB3b, a type II methanotroph, contains two forms of MMOs.

The membrane-bound or insoluble form, particulate monooxygenase termed as pMMO, and
cytoplasmic; or soluble form termed as sMMO. Their synthesis depends on the growth
conditions. The first form exhibits activity at high concentrations of copper ions. The second
one is active at low concentrations or a total lack of copper ions.
The content of bacteria is determined by measuring the optical density (OD540) of the post-
reaction mixture. It is necessary to perform calibration and draw the calibration curve
representing the dependence of optical density on the bacteria concentration in a solution. For
this purpose, bacteria Methylosinus trichosporium OB3b are cultivated for nine days on a
mineral medium with the composition described in the Methylosinus trichosporium OB3b
culture, containing 1.00 × 10−6 mol dm−3 Cu2+. The samples optical density measurements are
performed every 24 h. The amount of bacteria is determined in a Thoma chamber.
The process of methane oxidation to methanol by Methylosinus trichosporium OB3b bacteria
proceeds most effectively when carried out in a nutrient medium containing 1.0 × 10−6 mol
dm−3 of copper. Under these conditions, a satisfactory growth of biomass was also achieved.
It is noteworthy that the biochemical oxidation of methane to methanol by applying whole
cells of Methylosinus trichosporium OB3b bacteria is carried out at the temperature of 30°C.
3.2.2.2 Techno-economic appraisal of alternative processes/schemes

• Production of methanol through hydrogenation of carbon dioxide is preferable over

the others
• Currently in industry production of methanol though Natural gas process is dominant
but with time hydrogenation of carbon dioxide will become dominant on the basis of
availability of raw material and lesser cost of production.
• Reaction conditions in Natural gas process are harsh which incurs more operating cost
and high fixed cost for reforming.
• Carbon dioxide hydrogenation requires less temperature and pressure and hence is
economically viable.
Table 3.5: Techno-economic appraisal
Parameter CO2 Hydrogenation Natural gas process Biosynthesis

process
Feedstock Carbon dioxide and Natural Gas Methane oxygen

Hydrogen
Process 220 - 280⁰C and pressure of 200 – 300⁰C and pressure of 30⁰C
condition 20–30 bar 40 – 110 bar
Unit Reaction, Distillation, heat Reaction, Distillation, heat Reaction, Heat

operations transfer transfer transfer
Products Methanol and water Methanol and water Methanol, water
3.2.2.3 Status of technologies/schemes available
Table 3.6: Status of technologies
Technology Status
CO2 Hydrogenation Process Plant Available (the George Olah plant in Iceland,
owned by Carbon Recycling International (CRI))
Natural gas process Process Plants Available
Biosynthesis process In Lab Stage

3.2.2.4 Selection of technology/schemes
Basis of Selection
• The selected method is the Hydrogenation of Carbon dioxide.

• The selection is made based on the high selectivity and yield of the desired product
under the maintained process conditions.
• At the core of the advantages is that the reaction impurities are limited to only water
and dissolved CO2 in the crude methanol.
• The selectivity of biosynthesis is very low.
• Reaction conditions of hydrogenation are mild compared to the conventional method
by natural gas.
• CO2 is a threat to the environment and converting it directly to a useful product like
methanol makes this method environment friendly.
Details of Selected Process
inertness.
The main products of CO2 hydrogenation over Cu based catalysts are methanol, water and
CO.
If the temperature is increased further reverse water gas reaction occurs, which is not
desirable as it reduces the selectivity of methanol.
CO2 + H2 → CO + H2O ΔH0298K = +41.2 kJ/mol

Catalyst:
Methanol
and after studying Selectivity, Yield, Conversion and reaction conditions of these catalysts.
We have decided to use Cu-Zr-Ce (35− 19.7–45.3) catalyst.
Process Conditions:
Temperature: 220°C to 280°C
Pressure: 3 MPa
In terms of reactant ratio, for H2/CO2 higher than the stoichiometric value, methanol
selectivity is promoted while the formation of by-products (CO and H2O) is inhibited.
Flow Diagram:
Figure 3.6: Process Flow Diagram
3.2.2.5 Source of knowhow of selected process/technology

• Efficient approaches to overcome challenges in material development for
conventional and intensified CO2 catalytic hydrogenation to CO, methanol, and DME
by Thi Thanh Nguyet Vu et al.
• State of the art and perspectives in heterogeneous catalysis of CO2 hydrogenation to
methanol by Jiawei Zhong et al.
• Effect of the nature of copper species on methanol synthesis from CO2 hydrogenation
reaction over CuO/Ce0.4Zr0.6O2 catalyst by Weiwei Wang et al.

3.2.3 Raw Materials
3.2.3.1 Detailed Specifications
1. Hydrogen
Hydrogen is the chemical element with the symbol H and atomic number 1.
Hydrogen is the lightest element. At standard conditions, hydrogen is a gas of
diatomic molecules having the formula H2. It is colourless, odourless, non-toxic, and
highly combustible. Hydrogen is the most abundant chemical substance in the
universe, constituting roughly 75% of normal matter. Most of the hydrogen on Earth
exists in molecular forms such as water and organic compounds. For the most
common isotope of hydrogen (symbol 1H), each atom has one proton, one electron,
and no neutrons.
Hydrogen is nonmetallic, except at extremely high pressures, and readily forms a

single covalent bond with most nonmetallic elements, forming compounds such as
water and nearly all organic compounds. Hydrogen plays a vital role in acid-base
reactions because these reactions usually involve the exchange of protons between
soluble molecules. Hydrogen gas was first artificially produced in the early 16th
century by the reactions of acids on metals. In 1766–81, Henry Cavendish was the
first to recognize that hydrogen gas was a discrete substance and that it produces
water when burned, the property for which it was later named: in Greek, hydrogen
means “water-former”.
Industrial production is mainly from steam reforming natural gas and less often from
more energy-intensive methods such as the electrolysis of water. Most hydrogen is
used near the site of its production, the two most prominent uses being fossil fuel
processing (e.g., hydrocracking) and ammonia production, primarily for the fertilizer
market. Hydrogen is problematic in metallurgy because it can embrittle many metals,
complicating the design of pipelines and storage tanks.
Chemical properties of Hydrogen:

Table 3.7: Properties of Hydrogen
Symbol H
Atomic number 1
Atomic mass 1.007825 g.mol-1
Density 0.0899*10-3 g.cm-3 at 20 °C
Melting point - 259.2 °C
Boiling point - 252.8 °C
Refractive Index 1.000132
Production of Hydrogen:
a) Electrolysis of water
The electrolysis of water is a simple method of producing Hydrogen. A low
voltage current is run through the water, and gaseous oxygen forms at the
anode while gaseous hydrogen forms at the cathode. Typically, the cathode is
made from platinum or another inert metal when producing hydrogen for
storage. The theoretical maximum efficiency (electricity used vs energetic
value of hydrogen produced) is in the range of 88–94%.
2 H2O(l) → 2 H2(g) + O2(g)
b) Methane pyrolysis (industrial method)

Methane pyrolysis uses methane CH4 bubbled up through the molten metal
catalyst at high temperatures (1340 K, 1065 °C or 1950 °F) to produce non-
polluting hydrogen H2 gas in high volume at low cost and produces non-
polluting solid carbon C with no emission of greenhouse gas.

CH4(g) → C(s) + 2 H2(g) ΔH° = 74 kJ/mol
Other methods such as Metal-Acid reaction, Bosch Process, Electrolysis of brine are
also used to produce hydrogen.
2. Carbon dioxide (CO2)
Carbon dioxide is an acidic colourless gas with a density about 53% higher than that
of dry air. Carbon dioxide molecules consist of a carbon atom covalently double
bonded to two oxygen atoms. It occurs naturally in Earth's atmosphere as a trace gas.
The current concentration is about 0.04% (412 ppm) by volume, rising from pre-
industrial levels of 280 ppm. Natural sources include volcanoes, hot springs and
geysers, and it is freed from carbonate rocks by dissolution in water and acids.
Because carbon dioxide is soluble in water, it occurs naturally in groundwater, rivers
and lakes, ice caps, glaciers and seawater. It is present in deposits of petroleum and
natural gas. Carbon dioxide has a sharp and acidic odour and generates the taste of
soda water in the mouth. However, at normally encountered concentrations, it is
odourless.
As the source of available carbon in the carbon cycle, atmospheric carbon dioxide is
the primary carbon source for life on Earth. Since late in the Precambrian, its
concentration in Earth's pre-industrial atmosphere has been regulated by
photosynthetic organisms and geological phenomena. Plants, algae and cyanobacteria
use energy from sunlight to synthesize carbohydrates from carbon dioxide and water
in a process called photosynthesis, which produces oxygen as a waste product. In turn,
oxygen is consumed, and CO2 is released as waste by all aerobic organisms when
they metabolize organic compounds to produce energy by respiration. Since plants
require CO2 for photosynthesis, and humans and animals depend on plants for food,
CO2 is necessary for the survival of life on earth.
Chemical properties of Carbon Dioxide:

Table 3.8: Properties of Carbon dioxide
Molecular Formula CO2
Molecular mass 44.01 g.mol-1
Density 1.8393 kg.m-3 at 20 °C
Melting point -56.6 °C at 5.185 bar
Boiling point - 78.5 °C at 1.01325 bar
Refractive Index 1.00045
Production of Carbon Dioxide:
a) Combustion of Carbon-based fuels:

The combustion of all carbon-based fuels, such as methane (natural gas),
petroleum distillates (gasoline, diesel, kerosene, propane), coal, wood and
generic organic matter produces carbon dioxide and, except in the case of pure
carbon, water. As an example, the chemical reaction between methane and
oxygen:
CH4 + 2O2 → CO2 + 2H2O
b) Thermal decomposition of limestone:

It is produced by thermal decomposition of limestone, CaCO3 by heating
(calcining) at about 850 °C (1,560 °F), in the manufacture of quicklime
(calcium oxide, CaO), a compound that has many industrial uses:
CaCO3 → CaO + CO2
c) Fermentation of sugar:
Carbon dioxide is a by-product of the fermentation of sugar in the brewing of

beer, whisky and other alcoholic beverages and in bioethanol production.

Yeast metabolizes sugar to produce CO2 and ethanol, also known as alcohol,
as follows:
C6H12O6 → 2CO2 + 2C2H5OH
d) Aerobic Organisms
All aerobic organisms produce CO2 when they oxidize carbohydrates, fatty acids,
and proteins. The large number of reactions involved are exceedingly complex
and not described easily. Refer to (cellular respiration, anaerobic respiration and
photosynthesis). The equation for the respiration of glucose and other
monosaccharides is:
C6H12O6 + 6O2 → 6CO2 + 6H
3.2.3.2 Requirement of raw materials
Assumptions
• The feed contains no chemical impurity.
• No leakage or loss of material occurs.
• Methanol to be produced = 30,000 MTPA
• The exact composition (weight percentage) of the raw materials is not known to us yet
but we will be working on it.
3.2.3.3 Availability: Indigenous/Imported
Hydrogen
The current global demand for hydrogen is 70 million metric tons per year; in energy terms,
its
around 330 million tonnes. Most of which is being produced from fossil fuels (76% from
natural

gas and around 23% from coal, remaining from the electrolysis of water) which consumes
6% of the global natural gas and 2% of the global coal. All this results in CO2 emissions of
around 830MT/year.
At present, India produces around 6.7 MT of hydrogen annually. A report published by

The Energy and Resources Institute anticipates the demand to reach 23 MT in 2050. The
current price of hydrogen in the country ranges from INR 340 to 400 per kg.
Key Producers of Hydrogen in India:

• Praxair India Pvt. Ltd.
• Linde India Limited
• INOX Air Products
• Bhuruka Gases Limited
• Air Liquide (Air Liquide India)
• Aditya Birla Chemicals (India) Ltd.
• Gujarat Alkalies And Chemicals Limited
• DCW Limited (DCW)
• Tata Chemicals Limited
• GHCL LTD
Imports of Hydrogen 2016-17 to 2020-21 QTY in Tonne & VAL in Rs. Lakh
Table 3.9: Imports of Hydrogen
2016-17 2017-18 2018-19 2019-20 2020-21
QTY VAL QTY VAL QTY VAL QTY VAL QTY VAL
0.1 22.1 0.05 3.53 4.1 8.94 250.15 275.71 0.01 1.56
Exports of Hydrogen 2016-17 to 2020-21 QTY in Tonne & VAL in Rs. Lakh
Table 3.10: Exports of Hydrogen
2016-17 2017-18 2018-19 2019-20 2020-21

12.71 11.81 25.58 61.48 32.86 36.53 9.5 16.69 3.19 5.85
Carbon Dioxide
While most of the focus on CO2 is on its contribution to climate change, it can also be a
commercial input to various products and services. Today, around 230 million tonnes (MT)
of CO2 are used each year.
Carbon dioxide manufacturers are now concentrating on carbon capture and utilization.
Producers capture carbon dioxide produced by the combustion of fossil fuels, which is then
used for EOR (Enhanced Oil Recovery) in the oil & gas industry and in the production of
sodium bicarbonate, which, in turn, is used in food, beverage, and pharmaceutical industries.
Tata Steel has commissioned a 5 tonnes per day (TPD) carbon capture plant at its Jamshedpur
Works, making it the country’s first steel company to adopt a carbon capture technology that
extracts CO2 directly from the Blast Furnace gas. Tata Steel will reuse the captured CO2 on-
site to promote the circular carbon economy.
This Carbon Capture and Utilisation (CCU) facility uses amine-based technology and makes
the captured carbon available for onsite reuse. The depleted CO2 gas is sent back to the gas
network with increased calorific value. This project has been executed with technological
support from Carbon Clean, a global leader in low-cost CO2 capture technology.
Key Producers of Carbon Dioxide:
• Linde Group
• Abdullah Hashim Industrial & Equipment Co.
• Bristol Gases
• Dubai Industrial Gases
• MohsinHiader LLC
• Ellenbarrie Industrial Gases

• Matheson Tri Gas Inc.

• SICGIL India Limited
Imports of Carbon Dioxide 2016-17 to 2020-21 QTY in Tonne & VAL in Rs. Lakh
Table 3.11: Imports of Carbon Dioxide
2016-17 2017-18 2018-19 2019-20 2020-21
157.43 425.43 168.02 459.31 267.19 901.10 175.01 507.82 417.08 418.23
Exports of Carbon Dioxide 2016-17 to 2020-21 QTY in Tonne & VAL in Rs. Lakh
Table 3.12: Exports of Carbon Dioxide
2016-17 2017-18 2018-19 2019-20 2020-21
10,551.44 1,400.56 10,038.28 1,113.26 10,589.79 1,227.95 9,495.02 1,131.68 7,725.78 895.13
Catalyst
We are using a copper-based catalyst (Cu-Zr-Ce) for our process. Since the catalyst is well
known, they are readily available in the market.
3.2.3.4 Government policies for import of raw material
India has a federal government structure under which the Indian government and
governments at the state level can enact legislation on the subjects reserved for them under
the Constitution of India. Under the Constitution, the regulation and development of oilfields,

mineral oil resources, petroleum, and petroleum products fall within the jurisdiction of the
parliament, that is, the central legislative body in India.
The Oilfields (Regulation and Development) Act 1948 deals with issuing petroleum
exploration licences (PEL), petroleum mining leases (PML) and collection of royalties. The
Petroleum and Natural Gas Rules 1959 (PNG Rules) regulate the grant of PELs and PMLs
for petroleum and natural gas that belong to the government and for their conservation and
development. In addition, the Territorial Waters, Continental Shelf, Exclusive Economic
Zone and the Maritime Zones Act 1976 provides for granting licences by the government to
explore and exploit the resources of the continental shelf and Exclusive Economic Zone.
The permission to construct oil and gas pipelines by PNGRB under PNGRB (Authorising
Entities to Lay, Build, Operate or Expand Petroleum and Petroleum Products Pipeline)
Regulations 2010 and PNGRB (Authorising Entities to Lay, Build, Operate or Expand
Natural Gas Pipelines) Regulations 2008 also contain conditions relating to operations.
Carbon Capture, Utilization, and Storage programme:

This Program by the Department of Science and Technology aims to reduce carbon emission
by either storing or reusing it so that captured carbon dioxide does not enter the atmosphere.
It will emphasize research and development and capacity building of both human resources
and infrastructure to evolve technologies and methodologies that address issues related to
high capital costs, safety, logistics and high auxiliary power consumption.
CCUS can achieve significant CO2 reductions from power plants (fuelled by coal, natural
gas, and biomass) and industrial applications.
Government Duty for the required raw materials are as follows:
Table 3.13: Taxation of Raw Materials
Product Name HS Code Basic Duty CVD SPL. CVD
Hydrogen 28041000 5% 18% 10%
Carbon Dioxide 28112190 10% 18% 10%

3.2.3.5 Prevailing Prices
1. Hydrogen
The current cost of green hydrogen produced by electrolysis is estimated at around
₹350 per kg; India’s green hydrogen plan is to more than halve it to ₹160 per kg by
2029-30.
2. Carbon dioxide
The current price of Carbon dioxide is ₹30-40 per kg.
3.2.3.6 Testing procedures for the raw materials:
1. Hydrogen: ASTM D7941 / D7941M - 14: Standard Test Method for Hydrogen
Purity Analysis Using a Continuous Wave Cavity Ring-Down Spectroscopy Analyzer
2. Carbon dioxide: ASTM D4984 - 20: Standard Test Method for Carbon Dioxide in
Natural Gas Using Length-of-Stain Detector Tubes
3.3 Material and Energy Flow Information

Flow Chart:
Figure 3.7: Process Flow Diagram
Process:

inertness.
The main products of CO2 hydrogenation over Cu based catalysts are methanol and water.
Catalyst:
Methanol and after studying Selectivity, Yield, Conversion and reaction conditions of these
catalysts. We have decided to use Cu-Zr-Ce (35− 19.7–45.3) catalyst.
Process Conditions:
Temperature: 240°C
Pressure: 3 MPa
Material and Energy balance

Assumptions:
• Feed contains Hydrogen and Carbon dioxide and no chemical impurity
• No leakage or loss of material occurs in the plant
• Design Basis: 300 days of operation per year
24 hours of operation per day
Capacity (1.0):
Methanol to be produced: 30000 * 1.0 MTPA = 30000 MTPA
Methanol to be produced per hour: 30000/ (300*24) * 1000=4167 kg/hr
UNIT 1: Compressor (C1)
Figure 3.8.1: Compressor

Table 3.14: Compressor Mass and Energy Flow Information
CO2 S5
Mole Flows(kmol/hr)
CO2 472.5 472.5
H2 0 0
METHANOL 0 0
WATER 0 0
Total Flow (kmol/hr) 472.5 472.5
Total Flow (kg/hr) 20794.6 20794.6
Volume Flow (l/min) 193857.4 14915.9
Mole Fractions
CO2 1 1
H2 0 0
METHANOL 0 0
WATER 0 0
Temperature (°C) 26.85 410.28
Pressure (bar) 1.01325 30
Molar Vapor Fraction 1 1
Molar Liquid Fraction 0 0
Molar Solid Fraction 0 0
Enthalpy Balance
Molar Enthalpy (cal/mol) -93971.77 -89936.10
Mass Enthalpy (cal/gm) -2135.25 -2043.55
Molar Entropy (cal/mol-K) 0.74403 2.52876
Mass Entropy (cal/gm-K) 0.01690 0.05745
Molar Density (mol/cc) 4.0623E-05 0.00052
Mass Density (gm/cc) 0.00178 0.02323
Average MW 44.01 44.01

HYDROGEN S6
Mole Flows(kmol/hr)
CO2 0 0
H2 500 500
METHANOL 0 0
WATER 0 0
Total Flow (kmol/hr) 500 500
Total Flow (kg/hr) 1007.9 1007.9
Volume Flow (l/min) 205140.1 22447.2
Mole Fractions
CO2 0 0
H2 1 1
METHANOL 0 0
WATER 0 0
Temperature (°C) 26.85 698.78
Pressure (bar) 1.01325 30
Enthalpy Balance
Molar Enthalpy (cal/mol) 12.72 4734.99
Mass Enthalpy (cal/gm) 6.31 2348.84
Molar Entropy (cal/mol-K) 0.04252 1.55182
Mass Entropy (cal/gm-K) 0.02109 0.76980
Molar Density (mol/cc) 4.06226E-05 0.00037124
Mass Density (gm/cc) 8.18904E-05 0.00074838
Average MW 2.01588 2.01588
UNIT 3: Mixer (M1)
Figure 3.8.3: Mixer
Table 3.16: Mixer Mass and Energy Flow Information
S5 S6 S7 S10
Mole Flows(kmol/hr)

CO2 472.5 0 1646.9 1174.4

H2 0 500 681.7 181.7
METHANOL 0 0 27.8 27.8
WATER 0 0 6.2 6.2
Total Flow (kmol/hr) 472.5 500 2362.6 1390.1
Total Flow (kg/hr) 20794.6 1007.9 74855.1 53052.5
Volume Flow (l/min) 14916.0 22447.1 62631.0 27872.5
Mole Fractions
CO2 1 0 0.697 0.845
H2 0 1 0.288 0.131
METHANOL 0 0 0.011 0.020
WATER 0 0 0.003 0.005
Temperature (°C) 410.28 698.78 300.76 160.93
Pressure (bar) 30 30 30 30
Molar Vapor Fraction 1 1 1 1
Molar Liquid Fraction 0 0 0 0
Molar Solid Fraction 0 0 0 0
Enthalpy Balance
Molar Enthalpy (cal/mol) -89936.1 4734.99 -63675.79 -79356.34
Mass Enthalpy (cal/gm) -2043.55 2348.84 -2009.75 -2079.31
Molar Entropy (cal/mol-K) 2.53 1.55 0.72 -2.32
Mass Entropy (cal/gm-K) 0.05746 0.76980 0.02271 -0.06072
Molar Density (mol/cc) 0.000528 0.000371 0.000629 0.000831
Mass Density (gm/cc) 0.02323 0.00075 0.01992 0.03173
Average MW 44.01 2.02 31.68 38.16
UNIT 4: Heat Exchanger (H1)
Figure 3.8.4: Heat Exchanger
Table 3.17: Heat Exchanger Mass and Energy Flow Information
FEED S7

Mole Flows(kmol/hr)
CO2 1646.9 1646.9
H2 681.7 681.721984
METHANOL 27.78 27.7729395
WATER 6.2 6.21315617
Total Flow (kg/hr) 74855.1 74855.1067
Volume Flow (l/min) 56000.0 62631.0
Mole Fractions
CO2 0.697 0.697
H2 0.289 0.286
METHANOL 0.012 0.012
WATER 0.003 0.003
Temperature (°C) 240 300.76
Pressure (bar) 30 30
Enthalpy Balance
Molar Entropy (cal/mol-K) -0.3822 0.7196
Mass Entropy (cal/gm-K) -0.0121 0.0227
Molar Density (mol/cc) 0.000703 0.000629
UNIT 5: Reactor (B2)
Figure 3.8.5: Reactor

Table 3.18: Reactor Mass and Energy Flow Information
FEED S8
Mole Flows(kmol/hr)
CO2 1646.9 1495.4
H2 681.7 227.2
METHANOL 27.8 179.3
WATER 6.2 157.7
Total Flow (kg/hr) 74855.1 74855.1
Mole Fractions
CO2 0.697 0.726
H2 0.289 0.110
WATER 0.003 0.077
Temperature (°C) 240 240
Enthalpy Balance
Molar Entropy (cal/mol-K) -0.38224 -2.75279
Mass Entropy (cal/gm-K) -0.01206 -0.07574
S8 S16

Mole Flows(kmol/hr)
CO2 1495.4 1495.4
H2 227.2 227.2
WATER 157.7 157.7
Total Flow (kg/hr) 74855.1 74855.1
Mole Fractions
CO2 0.726 0.726
H2 0.110 0.110
WATER 0.077 0.077
Temperature (°C) 240 35
Molar Vapor Fraction 1 0.831
Molar Liquid Fraction 0 0.169
Enthalpy Balance
UNIT 7: Flash Unit 1 (FLASH-1)

Figure 3.8.7: Flash Unit
Table 3.20: Flash Unit Mass and Energy Flow Information
EFF S16 S21

Mole Flows(kmol/hr)
CO2 1468.0 1495.4 27.4
H2 227.2 227.2 0.029
METHANOL 34.7 179.3 144.6
WATER 7.8 157.7 150.0
Total Flow (kmol/hr) 1737.6 2059.6 322.0
Total Flow (kg/hr) 66315.6 74855.1 8539.5
Volume Flow (l/min) 76605.7 73266.6 166.9
Mole Fractions
CO2 0.849 0.726 0.085
H2 0.131 0.110 9.0624E-05
METHANOL 0.020 0.087 0.449
WATER 0.005 0.077 0.466
Temperature (°C) 45 35 45
Pressure (bar) 10 10 10
Molar Vapor Fraction 1 0.831 0
Molar Liquid Fraction 0 0.169 1
Molar Solid Fraction 0 0 0
Enthalpy Balance
Molar Enthalpy (cal/mol) -80445.2 -78206.0 -64974.2
Mass Enthalpy (cal/gm) -2107.8 -2151.76 -2449.6
Molar Entropy (cal/mol-K) -3.0464 -9.6316 -41.5725
Mass Entropy (cal/gm-K) -0.0798 -0.2650 -1.5673
Molar Density (mol/cc) 0.00038 0.00047 0.03215
Mass Density (gm/cc) 0.01443 0.01703 0.85270
Average MW 38.1648 36.3451 26.5242

UNIT 8: Splitter (B18)
Figure 3.8.8: Splitter
Table 3.21: Splitter Mass and Energy Flow Information
EFF PURGE RECYCLE

Mole Flows(kmol/hr)
CO2 1468.0 293.6 1174.4
H2 227.2 45.4 181.7
METHANOL 34.7 6.9 27.8
WATER 7.8 1.6 6.2
Total Flow (kg/hr) 66315.6 13263.1 53052.5
Volume Flow (l/min) 76605.7 15321.1 61284.5
Mole Fractions
CO2 0.845 0.845 0.845
H2 0.131 0.131 0.131
METHANOL 0.020 0.020 0.020
WATER 0.004 0.004 0.004
Temperature (°C) 45 45 45
Molar Vapor Fraction 1 1 1
Molar Liquid Fraction 0 0 0
Enthalpy Balance


Average MW 38.16 38.16 38.16
RECYCLE S10
Mole Flows(kmol/hr)
CO2 1174.4 1174.4
H2 181.7 181.7
METHANOL 27.8 27.8
WATER 6.2 6.2
Total Flow (kg/hr) 53052.5 53052.5
Mole Fractions
CO2 0.845 0.845
H2 0.131 0.131
WATER 0.004 0.004
Enthalpy Balance

UNIT 10: Valve (V1)
Figure 3.8.10: Valve
Table 3.23: Valve Mass and Energy Flow Information
S21 S22
Mole Flows(kmol/hr)
CO2 27.4 27.4
H2 0.03 0.03
WATER 150.0 150.0
Mole Fractions
CO2 0.085 0.085
H2 9.0624E-05 9.0624E-05
WATER 0.466 0.466
Pressure (bar) 10 2
Molar Vapor Fraction 0 0.076
Molar Liquid Fraction 1 0.924
Enthalpy Balance


UNIT 11: Flash Unit 2 (FLASH-2)
Figure 3.8.11: Flash Unit
Table 3.24: Flash Unit Mass and Energy Flow Information
PURGE2 S22 S28

Mole Flows(kmol/hr)
CO2 24.1 27.4 3.3
H2 0.03 0.03 3.6196E-05
METHANOL 6.5 144.6 138.06
WATER 1.7 150.0 148.3
Total Flow (kg/hr) 1300.7 8539.5 7238.9
Volume Flow (l/min) 7462.1 5447.9 148.0
Mole Fractions
CO2 0.747 0.085 0.011
H2 0.001 9.0624E-05 1.2498E-07
METHANOL 0.201 0.449 0.477
WATER 0.051 0.466 0.512
Temperature (°C) 60 41.24 60
Molar Vapor Fraction 1 0.076 0

Molar Liquid Fraction 0 0.924 1

Enthalpy Balance
Molar Density (mol/cc) 7.2204E-05 0.00098 0.03262
Average MW 40.23 26.52 24.99
S28 S29
Mole Flows(kmol/hr)
CO2 3.3 3.3
H2 3.6196E-05 3.6196E-05
WATER 148.3 148.3
Mole Fractions
CO2 0.0112 0.0112
H2 1.2498E-07 1.2498E-07
METHANOL 0.4767 0.4767
WATER 0.5121 0.5120
Pressure (bar) 2 2


Enthalpy Balance
UNIT 13: Distillation Column (DISTL)
Figure 3.8.13: Distillation Column
Table 3.26: Distillation Column Mass and Energy Flow Information
BOTTOM DISTIL S29

Mole Flows(kmol/hr)
CO2 0 3.3 3.3
H2 0 3.6196E-05 3.6196E-05
METHANOL 8.0 130.1 138.1
WATER 148.3 0 148.3


Total Flow (kg/hr) 2927.7 4311.2 7238.9
METHANOL (kg/hr) 255.9 4167.8 4423.6
Volume Flow (l/min) 55.9 90.5 141.3
Mole Fractions
CO2 0 0.0244 0.0112
H2 0 2.7148E-07 1.2498E-07
METHANOL 0.05109434 0.9756 0.4767
WATER 0.94890327 2.6107E-06 0.5121
Temperature (°C) 118.40 28.37 26.85
Pressure (bar) 2.1 1.9 2
Molar Vapor Fraction 0 0 0
Molar Liquid Fraction 1 1 1
Enthalpy Balance
Average MW 18.73 32.33 24.99
3.4 Detailed Design of Equipment

3.4.1 Process design of all major equipment
CONTENT
• Design of heat exchangers
• Design of flash column
• Design of reactor used in the plant
• Design of distillation column
ABSTRACT
In this section process design of all the major equipment has been discussed. Detailed process
design of 7 equipment has been presented. For design of reactors, catalyst and GHSV data
has been incorporated from various research papers. The reference has been mentioned at
appropriate places.

All the pieces of equipment are designed for the Capacity of 30000*C = 30000*0.9 = 27000
MTPA
Where C is the Capacity Multiplier
Heat Exchanger (H1) Process Design
Design for number of tubes, bundle diameter, shell diameter, tube side heat transfer
coefficient (HTC), shell side HTC, Overall HTC and pressure drop for shell side and tube
side (using Kern‘s Method).
Table 3.27 Properties of stream and HE layout specification
Properties of hot fluid

Property Value Unit
Inlet Temp 300 deg C
Outlet Temp 240 deg C
Mass Flowrate 18.77 kg/sec
Viscosity 0.000016 pa.s
Specific heat capacity 5.334 kJ/kg.K
Density 19.51 kg/m3
Thermal Conductivity 0.128 W/m.K
Properties of cold fluid
Property Value Unit
Inlet Temp 20 deg C
Density 1000 kg/m3
Step 1.
From mass balance,
Shell side mass flow rate, ms = 20.52 kg/s
Tube side mass flow rate, mt = 18.77 kg/s

Heat duty= 6006.08 KW
Step 2. LMTD and No. of Tubes
ΔT1 = 300-90=210°C
ΔT2 = 240-20=220°C
(𝛥𝑇1−𝛥𝑇2)
LMTD = 𝛥𝑇1 = 214.96°C
ln⁡( )
⁡𝛥𝑇2
Assumed U = 350 W/m2 °C [Fig 12.1 Coulson Richardson's Chemical Engineering Vol.6]
𝑄
Area Required = A = 𝑈∗𝐿𝑀𝑇𝐷 = 79.82946331 m2
Choosing 50.8mm OD, 45.3mm ID, 4.88m length [Table B.1 Chemical Engineering Design]
Surface Area of one tube = 0.7707 m2
𝐴𝑟𝑒𝑎⁡𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑
Number of tubes = 𝑆𝑢𝑟𝑓𝑎𝑐𝑒⁡𝐴𝑟𝑒𝑎⁡𝑜𝑓⁡𝑜𝑛𝑒⁡𝑡𝑢𝑏𝑒 = 100
𝜋𝑑2
Cross-section Area of one tube = 𝐴 = = 0.0016117 m2
4
Total tube area = Number of tubes* Cross-section Area of one tube = 0.16117 m2
Step 3. Tube side velocity
Using 1.25-inch triangular pitch and split ring floating head type and 1 tube pass.
Tube per Pass = 100
From Table 12.4, Coulson Richardson's Chemical Engineering Vol.6
k1 = 0.319
n1 = 2.142
1
𝑁𝑡(𝑛1)
Bundle diameter Db = 𝑑𝑜⁡ ∗ ⁡ 𝑘1 = 743.41 mm
Clearance = 65 mm [Fig 12.10 Coulson Richardson's Chemical Engineering Vol.6]
Shell Diameter Ds = Db + Clearance = 808.41 mm
L/D = 6.0366

As L/D ratio is between 5 and 10, the Design is acceptable.
Area per pass = 0.1612 m2
Volumetric Flow = 0.9619 m3/s
Tube Side Velocity ut = 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐⁡𝐹𝑙𝑜𝑤/𝐴𝑟𝑒𝑎⁡𝑝𝑒𝑟⁡𝑝𝑎𝑠𝑠 = 5.9682 m/s
As the Tube side velocity is in the range of 5 m/s to 10 m/s for gases, the design is acceptable
Step 4. Tube side heat transfer coefficient
de = di = 45.3 mm
C = 0.021 [Eq 12.11 Coulson Richardson's Chemical Engineering Vol.6]
𝜌𝑣𝑑𝑒
Re = = 329669.73
𝜇
𝜇𝐶𝑝
Pr = = 0.66675
𝑘
Fouling factor Coefficient = 5000 W/m2°C
[Table 12.2 Coulson Richardson's Chemical Engineering Vol.6]
𝜇 0.14 ℎ𝑡 𝑑
Nu = 𝐶 ∗ 𝑅𝑒 0.8 ∗ Pr 0.33 ∗ (𝜇 ) ⁡⁡=
𝑤 𝑘
ht = 754.66 W/m2°C
Step 5. Shell side heat transfer coefficient

Baffle spacing Lb = 0.3* Ds = 242.52 mm
Tube pitch = Pt = 1.25*do = 63.5 mm
Cross flow area (As) = 0.0392 m2
Shell Side Velocity us = 0.5232 m/s
(𝑃𝑡2 ⁡−⁡0.917∗𝑑𝑜2 )
Equivalent diameter = de = 1.10 ∗ = 36.0705 mm
𝑑𝑜
𝜌𝑣𝑑𝑒
Re = = 18873.34827
𝜇
𝜇𝐶𝑝
Pr = = 6.97
𝑘

Taking Baffle Cut as 25%
jh = 0.0045 [Fig. 12.29 Coulson Richardson's Chemical Engineering Vol.6]
ℎ𝑠⁡ 𝑑𝑒 1⁄ 𝜇 0.14
Nu = = 𝑗ℎ 𝑅𝑒𝑃𝑟 3( )
𝑘𝑓 𝜇𝑤
hs = 2696.85 W/m2°C
Fouling factor Coefficient = 3000 W/m2 °C
Step 6. Overall coefficient
kw = 30 Btu/hft °F = 51.9 W/m °C [Table A.16 Chemical Engineering Design]
𝑑
1 1 1 𝑑𝑜 ⁡𝑙𝑛( 𝑜 ) 𝑑𝑜 1 𝑑𝑜 1
𝑑𝑖
⁡= ⁡ ⁡+⁡ ⁡+⁡ ⁡+⁡ ⁡×⁡ ⁡+⁡ ⁡×
𝑈 ℎ𝑜 ℎ𝑜𝑑 2𝑘𝑤 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖
U0 = 404.78 W/m2 °C
Step 7. Tube side pressure drop

𝐿 𝜇 −0.14 𝜌𝑢𝑡2
ΔPt = 𝑁𝑝 [8𝑗𝑓 (𝑑 ) (𝜇 ) + 2.5]( )
𝑖 𝑤 2
jf = 0.0022 [Fig. 12.24 Coulson Richardson's Chemical Engineering Vol.6]
ΔPt = 2044.03 Pa = 0.02044 bar
Step 8. Shell side pressure drop

𝐷 𝐿 𝜌𝑢𝑠2 𝜇 −0.14
Δ𝑃𝑠 = 8𝑗𝑓 (𝑑 𝑠 ) (𝐿 ) ( ) (𝜇 )
𝑒 𝑏 2 𝑤
Δ𝑃𝑠 = 465.5180705 Pa = 0.00466 bar


Property Value Unit
Inlet Temp 240 deg C
Density 24.9 kg/m3
Property Value Unit
Inlet Temp 20 deg C
Density 1000 kg/m3
Step 1.
From mass balance,
ΔT1 = 240-50=190°C
ΔT2 = 35-20=15°C
LMTD = 𝛥𝑇1 = 68.93°C
ln⁡( )
⁡𝛥𝑇2

𝑄
Area Required = A = 𝑈∗𝐿𝑀𝑇𝐷 = 425.5751565m2
Choosing 25.4 mm OD, 19.9 mm ID, 4.32 m length [Table B.1 Chemical Engineering
Design]
Surface Area of one tube = 0.5801m2
𝜋𝑑2
Cross-section Area of one tube = 𝐴 = = 0.000311m2
4
Total tube area = Number of tubes* Cross-section Area of one tube = 0.22705m2
Using 1.25-inch triangular pitch and split ring floating head type and 2 tube passes.
Tube per Pass = 365
k1 = 0.249
n1 = 2.207
1
𝑁𝑡(𝑛1)
L/D = 7.200
As the Tube side velocity is in the range of 5 m/s to 10 m/s for gases, the design is acceptable
de = di = 19.9 mm

𝜌𝑣𝑑𝑒
Re = = 32211.77
𝜇
𝜇𝐶𝑝
Pr = = 2.2275
𝑘
𝜇 0.14 ℎ𝑡 𝑑
Nu = 𝐶 ∗ 𝑅𝑒 0.8 ∗ Pr 0.33 ∗ ( ) ⁡⁡=
𝜇𝑤 𝑘
ht = 565.55 W/m2°C

(𝑃𝑡2 ⁡−⁡0.917∗𝑑𝑜2 )
𝑑𝑜
𝜌𝑣𝑑𝑒
Re = = 27189.99
𝜇
𝜇𝐶𝑝
Pr = = 6.97
𝑘
ℎ𝑠⁡ 𝑑𝑒 1⁄ 𝜇 0.14
𝑘𝑓 𝜇𝑤
hs = 6216.367 W/m2°C

𝑑
1 1 1 𝑑𝑜 ⁡𝑙𝑛( 𝑜 ) 𝑑𝑜 1 𝑑𝑜 1
𝑑𝑖
⁡= ⁡ ⁡+⁡ ⁡+⁡ ⁡+⁡ ⁡×⁡ ⁡+⁡ ⁡×
U0 = 326.149 W/m2 °C

𝐿 𝜇 −0.14 𝜌𝑢𝑡2
ΔPt = 𝑁𝑝 [8𝑗𝑓 (𝑑 ) (𝜇 ) + 2.5]( )
𝑖 𝑤 2
ΔPt = 18745.49 Pa = 0.187455 bar

𝐷 𝐿 𝜌𝑢𝑠2 𝜇 −0.14
Δ𝑃𝑠 = 8𝑗𝑓 (𝑑 𝑠 ) (𝐿 ) ( ) (𝜇 )
𝑒 𝑏 2 𝑤
Δ𝑃𝑠 = 7057.294 Pa = 0.07057 bar

Property Value Unit
Inlet Temp 60 deg C
Outlet Temp 26.85 deg C
Density 853 kg/m3


Property Value Unit
Inlet Temp 20 deg C
Density 1000 kg/m3
Step 1.
From mass balance,
ΔT1 = 60-30=30°C
ΔT2 = 26.85-20=6.85°C
LMTD = 𝛥𝑇1 = 15.67°C
ln⁡( )
⁡𝛥𝑇2
𝑄
Area Required = A = 𝑈∗𝐿𝑀𝑇𝐷 = 15.2836 m2
Choosing 12.7 mm OD, 10.2 mm ID, 2.44 m length [Table B.1 Chemical Engineering
Design]
Surface Area of one tube = 0.0954 m2
𝜋𝑑2
Cross-section Area of one tube = 𝐴 = = 0.00008171 m2
4

Total tube area = Number of tubes * Cross-section Area of one tube = 0.01307 m2
Using 1.25-inch triangular pitch and split ring floating head type and 8 tube passes.
Tube per Pass = 20
k1 = 0.0365
n1 = 2.675
1
𝑁𝑡(𝑛1)
L/D = 7.0337
As the Tube side velocity is in the range of 1 m/s to 2 m/s for process fluids, the design is
acceptable
de = di = 10.2 mm
𝜌𝑣𝑑𝑒
Re = = 22332.024
𝜇
𝜇𝐶𝑝
Pr = = 4.3227
𝑘

𝜇 0.14 ℎ𝑡 𝑑
Nu = 𝐶 ∗ 𝑅𝑒 0.8 ∗ Pr 0.33 ∗ (𝜇 ) ⁡⁡=
𝑤 𝑘
ht = 3862.27 W/m2°C

(𝑃𝑡2 ⁡−⁡0.917∗𝑑𝑜2 )
𝑑𝑜
𝜌𝑣𝑑𝑒
Re = = 6438.76
𝜇
𝜇𝐶𝑝
Pr = = 6.97
𝑘
ℎ𝑠⁡ 𝑑𝑒 1⁄ 𝜇 0.14
𝑘𝑓 𝜇𝑤
hs = 6051.867 W/m2°C
𝑑
1 1 1 𝑑𝑜 ⁡𝑙𝑛( 𝑜 ) 𝑑𝑜 1 𝑑𝑜 1
𝑑𝑖
⁡= ⁡ ⁡+⁡ ⁡+⁡ ⁡+⁡ ⁡×⁡ ⁡+⁡ ⁡×
U0 = 911.754 W/m2 °C


𝐿 𝜇 −0.14 𝜌𝑢𝑡2
ΔPt = 𝑁𝑝 [8𝑗𝑓 (𝑑 ) (𝜇 ) + 2.5]( )
𝑖 𝑤 2
ΔPt = 67762.31 Pa = 0.6776 bar

𝐷 𝐿 𝜌𝑢𝑠2 𝜇 −0.14
Δ𝑃𝑠 = 8𝑗𝑓 (𝑑 𝑠 ) (𝐿 ) ( ) (𝜇 )
𝑒 𝑏 2 𝑤
Δ𝑃𝑠 = 3919.85 Pa = 0.03920 bar
Flash Unit (FLASH-1) Process Design
Temperature = 45 °C
Pressure = 1000 kPa
Using Antoine equation, ln Psat = A – B/(T+C) where Psat is in mm Hg and T is in Kelvin
Table 3.30 Flash drum calculations
Component A B C log Psat (mmHg)

CO2 7.5322 835.06 268.223 4.866176113
CH3OH 8.07247 1574.99 238.86 2.5239954
H2 5.92088 71.6153 276.34 5.698015433
H2O 8.140191 1810.94 244.485 1.884460997
For V=1
Table 3.31 Flash Drum calculations
Component Psat (KPa) Ki Zi Zi Ki/(1+V(Ki-1))

CO2 9796.657678 9.796657678 0.707 0.707
CH3OH 44.55507919 0.04455507919 0.133 0.133
H2 66514.64123 66.51464123 0.085 0.085

H2O 10.2179275 0.0102179275 0.075 0.075
Ki = Psat/ Ptotal
Zi = mole fraction in entering stream

Summation of last column in above table = 0.707 + 0.133 + 0.085 + 0.075 = 1
Density of liquid solution, ρL = 867.3 kg/m3
Density of vapours, ρv = 14.5 kg/m3
(𝜌𝑙 −𝜌𝑣 )
Flooding velocity = 0.07 ∗ [ ] = 0.5368 m/s
𝜌𝑣
In case of no demister pad, velocity becomes 0.15 times 0.5368 m/s equal to 0.0805m/s
represented by uta
uta = 0.0805 m/s
Liquid Volume Flow Rate VL = 149.6 l/min = 0.00245 m3/s
Vapour Volume Flow Rate Vv = 71213 l/min = 1.1869 m3/s
Minimum vessel diameter:

𝜋𝐷 2 𝑢𝑡𝑎
= 1.1869
4
D = 4.3320 m
Assuming hold up time to be 10 min.

Volume of liquid = 10*60*0.00245= 1.4960 m3
Liquid depth required, hL = 1.4960/ (𝜋𝐷2 /4) = 0.101496 m
Therefore, height of flash tank = 2(D) + hL = 8.7656 m
Material of construction used is carbon steel.
Flash Unit (FLASH-2) Process Design
Temperature = 45 °C
Pressure = 1000 kPa

Using Antoine equation, ln Psat = A – B/(T+C) where Psat is in mm Hg and T is in Kelvin
Table 3.32 Flash drum calculations
Component A B C log Psat (mmHg)

CO2 7.5322 835.06 268.223 4.988015101
CH3OH 8.07247 1574.99 238.86 2.802477361
H2 5.92088 71.6153 276.34 5.707954686
H2O 8.140191 1810.94 244.485 2.192640218
For V=1
Table 3.33 Flash Drum calculations
Component Psat (KPa) Ki Zi Zi Ki/(1+V(Ki-1))

CO2 12969.3115 64.84655749 0.08 0.08
CH3OH 84.60171781 0.423008589 0.45 0.45
H2 68054.44653 340.2722327 0 0
H2O 20.77504808 0.1038752404 0.47 0.47
Ki = Psat/ Ptotal
Zi = mole fraction in entering stream

Summation of last column in above table = 0.08 + 0.45 + 0 + 0.47 = 1
Density of liquid solution, ρL = 815 kg/m3
Density of vapours, ρv = 2.9 kg/m3
(𝜌𝑙 −𝜌𝑣 )
Flooding velocity = 0.07 ∗ [ ] = 1.1714 m/s
𝜌𝑣
In case of no demister pad, velocity becomes 0.15 times 1.1714 m/s equal to 0.1757 m/s
represented by uta
uta = 0.1757 m/s
Liquid Volume Flow Rate VL = 133 l/min = 0.00222 m3/s

Vapour Volume Flow Rate Vv = 6465 l/min = 0.10775 m3/s
Minimum vessel diameter:

𝜋𝐷 2 𝑢𝑡𝑎
= 0.10775
4
D = 0.88362 m
Assuming hold up time to be 10 min.

Volume of liquid = 10*60*0.00222= 1.3300 m3
Liquid depth required, hL = 1.3300 / (𝜋𝐷2 /4) = 2.16885 m
Therefore, height of flash tank = 2(D) + hL = 3.9361 m
Material of construction used is carbon steel.
Reactor (B2) Process Design
Estimation of Residence Time (τ):
Residence time (τ) = Volume of reactor (V) / Volumetric flow rate (u)
The residence time is based upon the results obtained from the information and
calculations of the kinetics of the reactions involved. With the help of literature, we have
taken the residence time to be 3.182 s
Avg Residence time (τ) = 3.182 s
Calculation of Volumetric Flow Rate (u)

We know that,
ε = (uo – ui) / ui
Where:
ε = Expansivity (dimensionless)
uo = Outlet volumetric flow rate (m3/hr)
ui = Inlet volumetric flow rate (m3/hr)
Outlet mass flow rate = 67562.83 kg/hr
Inlet mass flow rate = 67562.83 kg/hr

outlet density = 19.5 kg/m3
inlet density = 21.8 kg/m3
Outlet volumetric flow rate (uo) = outlet mass flowrate / outlet density = 2713.37 m3/hr
Inlet volumetric flow rate (ui) = 3099.21 m3/hr
ε (epsilon) = -0.1245
Conversion Xa = 0.093 (from Catalyst data)
Now the volumetric flow rate is given by:
u = ui (1 + εXa)
u = 3063.33 m3/hr = 0.8509 m3/s
Calculation of Volume of Reactor (V)

The volume of the reactor is calculated as = Residence Time * Volumetric Flow Rate
V = 3.182 * 0.8509 = 2.7076 m3
Calculation of Length of Reactor (L)
For high rate of mixing and for reaction completion we take small length to diameter ratio as:
L / Di = 3.375
Where:
L = Length of the reactor (m)
Di = Internal diameter of the reactor (m)
L = 3.375 Di
As for the cylindrical shell, the volume is given by:

V = π/4 Di2 * L = 2.65Di3
Di = 1.0071 m
L = 3.375 * 1.0071 = 3.3990 m
Distillation Column (DISTIL) Process Design
From ASPEN PLUS Simulation we obtain the following parameters:

Feed (above tray) = 10
Lw (below feed) = 885.575 kmol/h
Vw (below feed) = 761.142 kmol/h
Lw (above feed) = 682.725 kmol/h
Vw (above feed) = 720.185 kmol/h
Bottom
Density of vapor = 0.97 kg/m3
Density of liquid = 945 kg/m3
Top
Density of vapor = 1.84 kg/m3
Density of liquid = 795 kg/m3
Determination of column diameter and height

𝜌
FLV = 𝐿/𝑉⁡√( 𝑣⁡)
𝜌𝑙
Top FLV = 0.045606
Bottom FLV = 0.037276
Take plate spacing as 0.6 m

From Fig 11.27, Coulson Richardson's Chemical Engineering Vol.6
K1 top = 0.11
K1 bottom = 0.12
Estimation of flood velocity

𝜌𝑙 ⁡−𝜌𝑣
𝑢𝑓 ⁡ = ⁡ 𝑘1 √(⁡ ⁡⁡) [Ref: Eq. 11.49 Sinnott & Towler, Vol.6]
𝜌𝑣 ⁡
Bottom uf = 3.7436 m/s
Top uf = 2.2838 m/s

Design for 85 per cent flooding at maximum flow rate

Bottom uf′ =3.1821 m/s
Top uf′ = 1.9413 m/s
Maximum volumetric flowrate
Top = 3.2617 m3/sec
Bottom = 3.9234 m3/sec
Top Area = 1.6802 m2
Bottom Area = 1.2330 m2
Taking downcomer area as 12 per cent of total.
Column Cross section area bottom = 1.4011 m2
Column Cross section area top = 1.9093 m2
Column Diameter base = 1.3356 m
Column Diameter top = 1.5592 m
Plate Design
Column Diameter Dc = 1.56 m
Column Area Ac = 1.9113 m2
Downcomer Area Ad = 0.12 * 1.9113 = 0.2294 m2 (at 12%)
Net area An = Ac – Ad = 1.9113 - 0.2294 = 1.6819 m2
Active area Aa = Ac – 2Ad = 1.9113 – 2*0.2294 = 1.4526 m2
Hole Area (Take 10% Aa as first trial)

Ah = 0.14526 m2
Weir Length = 0.76 * Dc = 1.1856 m
Take, Weir height = 50 mm
Hole Diameter = 5 mm
Plate thickness = 5 mm

Check Weeping
𝐿𝑚′∗𝑀𝑊
Maximum liquid rate = = 4.427875 kg/s
3600
At 70% turn-down,
Minimum liquid rate = 0.7*4.427875 = 3.0995 kg/s
2
𝐿𝑤 3
Maximum how = 750 ∗ [𝜌𝐿∗𝑙𝑤] [Ref: Eq. 11.53 Sinnott & Towler, Vol.6]
= 18.7476 mm Liquid
Minimum how = 14.7800 mm Liquid
At minimum rate,
hw + how = 50 + 14.78 = 64.78 mm
From figure 11.37 [Sinnott & Towler]

k2 = 30.6
Minimum design vapour velocity,

uh = 𝑘2 − 0.9⁡(25.4 − 𝑑ℎ )/√𝜌𝑣 = 12.4278 m/s
Actual minimum vapor velocity = 0.7 * Max base flow rate / Ah = 18.9064 m/s
Net actual minimum vapor velocity = 18.9064 m/s > 12.4278 m/s
Which is well above weep point.
Plate pressure drop
Maximum vapor velocity through holes = 27.01 m/s
From figure 11.42, for plate thickness / Hole diameter = 1, Ah/Ap = Ah/Aa = 0.1
C0 = 0.84
Dry plate pressure drop hd = 54.12 mm Liquid [Ref: Eq. 11.56 Sinnott & Towler, Vol.6]
Residual head hr = 13.23 mm Liquid
Total pressure Drop = 13.23 + 54.12 + 50 + 18.75 = 136.1 mm Liquid = Acceptable
Downcomer liquid back-up

Downcomer pressure drop,
Taking,
hap = hw – Lo = 40 mm
Area under apron, Aap = 0.0474 m2
This is less than Ad = 0.2294 m2 we will use Aap for hdc calculations
hdc = 2 mm Liquid [Eq. 11.92 Coulson Richardson Vol. 6]
Back-up in downcomer,
hb = 50 + 18.75 + 136.1 + 2 = 206.85 mm = 0.21 m
1
0.21 < 2 ⁡(𝑝𝑙𝑎𝑡𝑒⁡𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑤𝑒𝑖𝑟⁡ℎ𝑒𝑖𝑔ℎ𝑡)
0.21 < .325
So, plate spacing is acceptable.
Check residence time
tr = 52.34 s > 3s [Eq. 11.95 Coulson Richardson Vol. 6]
Satisfactory.
Check Entrainment
Uv = Vbottom * Bottom Area = 2.333 m/s
Percent flooding = Uv/(Bottom uf) = 62.31 %
From Fig. 11.29 [Coulson Richardson Vol. 6]
Sigma = 0.028 (well below 0.1)
Perforated area
Assuming cartridge – type construct
Unperforated edge strip = 50 mm
Wide calming zone = 50 mm

From Figure 11.32 for lw/Dc = 0.76
ϴc = 99°
Angle subtended by edge of plate = 180 - 99 = 81°
Mean length, unperforated edge strip = (1.56-0.05) * pi * 81 / 180 = 2.1347 m
Area of unperforated edge strips = 0.05*2.1347 = 0.10674 m2
Mean length of calming zone = 1.1856 + 0.05 = 1.2356 m
Area of calming zones = 0.12356 m2
Total area for perforations Ap = 1.2223 m2
Ah/Ap = 0.1188
From Figure 11.33 [Coulson Richardson Vol. 6], lp/dh = 2.75; satisfactory, within 2.5 to 4.0.
Number of holes
Area of one hole = 1.964⁡ ∗ ⁡ 10−5 = m2
0.1452
No of Holes = = 7396
1.964⁡∗⁡10−5
3.4.2 Mechanical Design of equipment

MECHANICAL DESIGN OF REACTOR
The vessel is being made of IS: 1570-1961 05 Cr18 Ni11 Mo3 quality steel having allowable
design stress value of 112.4 MN/m2. The head is designed with same material.
Minimum wall thickness required excluding any extra allowances
Maximum operating pressure (gauge) = 3 MN/m2
Design Pressure P=1.05*3 = 3.15 MN/m2
Shell inside Diameter (Di) = 1.0071 m (from Process Design)
Material of Construction = IS: 1570-1961 05 Cr18 Ni11 Mo3

f=allowable design stress for material specified==112.4*106 N/m2 (From IS: 1570-1961)
J= weld joint efficiency factor = 0.85

Length = 3.399 m (from Process Design)
𝑖 𝑃𝐷 ⁡
𝑡 = (2𝑓𝐽−𝑃)
𝑡 = 16.88 mm
Adding corrosion allowance of 3 mm to this minimum actual wall thickness required to be
ts = 19.88 mm
So, after rounding off thickness of 20 mm is selected.
Do = Di + 2*ts/1000 = 1.0471 m
Design of head
Material of construction is same as that of shell.

Assuming, Ri = Do
ri = 0.06*Ri = 0.06282 m
Assuming, Ri = Ro = Do = 1.0471 m
ri = ro = 0.06282 m
𝑝𝐷𝑜 𝐶
𝑡= Ref: Equation 4.2.20, Page 52, BC Bhattacharya
2𝑓𝑗
Since C is a function of t, we need to do the iterations.
hE is effective external height of head without straight flange and equal to least of the below
three:
𝐷 𝐷𝑜
ℎ𝑜 = 𝑅𝑜 ⁡ − ⁡ √(𝑅𝑜 − ⁡ 2𝑜 ⁡)(𝑅𝑜 + ⁡ − ⁡2𝑟𝑜 ) = 0.17731 m
2
𝐷𝑜2
= 0.26177 m
4𝑅𝑜
𝐷𝑜 𝑟𝑜
√ = 0.181364 m
2
Out of these three values calculated, the least value is taken as effective height (hE)

Taking J = 0.85,
Using table 4.1 (A), Page 53, BC Bhattacharya
Where hE / Do = 0.16934
t/Do = 0.0191
t = 0.0020585 m
tf = 1.06*(0.0020585+.003) = 0.005362 m
After rounding off thickness of 6 mm is selected for the head.
Nozzles and branch pipes
Compensation of Nozzles
Shell Nozzle
Material of construction: Same as that of the shell
f = 112.4 MN/m2
ts = 20 mm
tr = 0.000789 m
corrosion allowance = 0.003 m
dnozzle = 0.25 m
Do = 1.0171 m
Design Pressure PD = 3.15 MPa
Area to be compensated (A) = (d+2c) * tr = 0.000831 m2
Area available from shell (As) = (d + 2c) * (ts − tr − C) = 0.017072 m2
Area available from nozzle for reinforcement

An = Ao (no inside protrusion) = 2H1* (tn-tr`-c)
𝑝𝑑 𝑜
tr` = ⁡2𝑓𝐽+𝑝 = 16.982 mm
tn = 0.020 m

d (inside diameter of nozzle) =0.25 m
H1 = √(𝑑⁡ + ⁡2𝑐)(𝑡𝑛 ⁡ − ⁡𝑐) = 0.06597 m
An = 0.0000023933 m2
An + As = 0.0170743 m2
A is less than sum of As and An No ring pad is required
Design of flange for opening
Design Pressure = 3.15 MPa
Taking ―Asbestos filled corrugated metal jacket of stainless steel (Table7.1Page 103,BCB)
y = 45 MN/m2
m = 3.5
Minimum actual gasket width = 10 mm.

𝑑𝑜 ⁡ (𝑦−𝑝𝑚) 0.5
⁡ = ⁡ (⁡⁡(𝑦−𝑝(𝑚+1)⁡) = 1.04985
𝑑𝑖
di =B+0.01 = 1.05711 m (where B= shell outside diameter)
do = 1.10981 m
Gasket width = (do− di) / 2 = 26.35 mm
Gasket width, N = 26.35 mm

Basic Gasket seating width, bo = N/2 = 13.175 mm
Diameter at location of gasket load reaction, G = di + N = 1.0835 m
Estimation of bolt loads
Bolting Material – 5 % Cr Mo steel
Allowable stress of bolting material = 138 MN/m2
Load due to design Pressure:
H = 𝜋𝐺2P/4 = 2.9042 MN
Load to keep joint tight under operation:

Hp = πG(2b) mp = 0.9888 MN
Total operating load
Wo = H + Hp = 3.8930 MN
Load to seat gasket under bolting-up conditions,
Wg = πGby = 2.01798 MN
Wo is greater than Wg and therefore, Controlling load = 3.8930 MN
Minimum Bolting Area
S0 = 138 MN/m2
Where Sg = 138 MPa (Table 7.5 page 108 BCB)
Am = A0= Wo / S0 = 0.02821 m2
C2 = ID + 2(g1 + R) = 1.143706912
g1 =1.415 g0 = 28.3 (g0 = shell thickness)
R = Radial clearance from bolt circle to point of connection of hub or nozzle and back of
flange
Table 3.34: Bolt Specifications for Reactor
bolt size 0.012 m

bolt thickness 0.0015 m
R 0.02 m
rot area 0.00006364 m2
no. of bolts 444
Bs 0.075
C1 0.1909
C1-C2 -0.9528069116
Since C1 –C2 is negative for minimum bolt size, therefore flange is not required.
MECHANICAL DESIGN OF HEAT EXCHANGER
Heat Exchanger is assumed to be a cylindrical vessel under Internal Pressure.

Shell Thickness Calculations
Operating Pressure = 0.06965 atm
Design Pressure (PD) = 1.05 * 0.06965 = 0.07313 atm = 0.007313 MPa
Shell inside Diameter (Di) = 1.016 m (From Process Design)
Material of Construction = IS: 2002-1962 Grade 1

f = 110 MN/m2 (From IS: 2002-1962)
Length of vessel (L) = 7.32 m

𝑃 𝐷⁡
𝐷 𝑖
𝑡 = (2𝑓𝐽−𝑃 = 0.0397 mm
𝐷)
Weld joint efficiency factor, J = 0.85
Corrosive Allowance = 3 mm
Thus, thickness (t) = t + CA = 3.0397 mm
After rounding off, thickness = 5 mm
Do = Di + 2*t/1000 = 1.026 m
t/Di = 0.0049 < 0.25
Hence, assumption is valid; the vessel can be taken as membrane under internal pressure.
Head design
For the cylindrical design of exchanger, we have chosen Torispherical head

Material of construction is same as that of shell
Assuming, Ri = Do
Sf = 40 mm
ri = 0.06*Ri = 0.06156 m
ri = ro = 0.06156 m

𝑝𝐷𝑜 𝐶
2𝑓𝑗
three:
𝐷 𝐷𝑜
ℎ𝑜 = 𝑅𝑜 ⁡ − ⁡ √(𝑅𝑜 − ⁡ 2𝑜 ⁡)(𝑅𝑜 + ⁡ − ⁡2𝑟𝑜 ) = 0.17374 m
2
𝐷𝑜2
= 0.2565 m
4𝑅𝑜
𝐷𝑜 𝑟𝑜
√ = 0.17771 m
2
Taking J = 0.85,
Where hE / Do = 0.169338
t/Do = 0.0048733
t = 0.0008047 m
tf = 1.06*(0.0020585+.003) = 0.004032982 m
Shell Nozzle
f = 110 MN/m2
ts = 5 mm
tr = 0.26921 m

dnozzle = 0.25 m
Do = 1.026 m

𝑝𝑑
𝑜
tr` = ⁡2𝑓𝐽+𝑝 = 0.040124 mm
tn = 0.016 m
d (inside diameter of nozzle) =0.25 m
H1 = √(𝑑⁡ + ⁡2𝑐)(𝑡𝑛 ⁡ − ⁡𝑐) = 0.05769 m
An = 0.001495279967 m2
An + As = 0.00328 m2
A is less than sum of As and An.
No ring pad is required
y = 45 MN/m2
m = 3.5

𝑑𝑜 ⁡ (𝑦−𝑝𝑚) 0.5
⁡ = ⁡ (⁡⁡(𝑦−𝑝(𝑚+1)⁡) = 1.000081315
𝑑𝑖
do = 1.03608 m

Gasket width = (do− di) / 2 = 0.04212 mm, less than 10 mm

H = 𝜋𝐺2P/4 = 0.006165 MN
Hp = πG(2b) mp = 0.00000351 MN
Wo = H + Hp = 0.0061688 MN
Wg = πGby = 0.0030846 MN
S0 = 138 MN/m2
Am = A0= Wo / S0 = 0.0000447 m2
C2 = ID + 2(g1 + R)
flange

Table 3.35: Bolt Specifications for Heat Exchanger
bolt size 0.012 m

R 0.02 m
rot area 0.00006364 m2
no. of bolts 1
Bs 0.075
C1 1.013
C1-C2 -0.06715
Since C1 – C2 is negative for minimum bolt size, therefore flange is not required.
MECHANICAL DESIGN OF FLASH DRUM
Flash Drum is assumed to be a cylindrical vessel under Internal Pressure.
Shell Thickness Calculations
Operating Pressure = 1.97385 atm
Design Pressure (PD) = 1.05 * 0.06965 = 2.0725425 atm = 0.20725425 MPa
Shell inside Diameter (Di) = 0.88362 m (From Process Design)
Material of Construction = IS: 2002-1962 Grade 1

f = 112.4 MN/m2 (From IS: 2002-1961)
Length of vessel (L) = 3.9361 m

𝑃 𝐷⁡
𝐷 𝑖
𝑡 = (2𝑓𝐽−𝑃 = 0.9593 mm
𝐷)
Weld joint efficiency factor, J = 0.85
Corrosive Allowance = 3 mm
Thus, thickness (t) = t + CA = 3.9593 mm
After rounding off, thickness = 5 mm
Do = Di + 2*t/1000 = 0.89362 m
t/Di = 0.005658 < 0.25

Hence, assumption is valid; the vessel can be taken as membrane under internal pressure.
Head design
For the cylindrical design of exchanger, we have chosen Torispherical head

Material of construction is same as that of shell
Assuming, Ri = Do
Sf = 40 mm
ri = 0.06*Ri = 0.05362 m
ri = ro = 0.05362 m
𝑝𝐷𝑜 𝐶
2𝑓𝑗
three:
𝐷 𝐷𝑜
ℎ𝑜 = 𝑅𝑜 ⁡ − ⁡ √(𝑅𝑜 − ⁡ 2𝑜 ⁡)(𝑅𝑜 + ⁡ − ⁡2𝑟𝑜 ) = 0.15132 m
2
𝐷𝑜2
= 0.2234 m
4𝑅𝑜
𝐷𝑜 𝑟𝑜
√ = 0.1548 m
2
Taking J = 0.85,
Where hE / Do = 0.16934
t/Do = 0.0055952
t = 0.002743 m
tf = 1.06*(0.0020585+.003) = 0.00608758 m

Shell Nozzle
f = 110 MN/m2
ts = 7 mm
tr = 0.9177 m
dnozzle = 0.25 m
Do = 0.8936 m

𝑝𝑑 𝑜
tr` = ⁡2𝑓𝐽+𝑝 = 0.968214 mm
tn = 0.016 m
d (inside diameter of nozzle) = 0.25 m
H1 = √(𝑑⁡ + ⁡2𝑐)(𝑡𝑛 ⁡ − ⁡𝑐) = 0.05769 m
An = 0.0013882 m2
An + As = 0.004161 m2
A is less than sum of As and An.
No ring pad is required

y = 45 MN/m2
m = 3.5

𝑑𝑜 ⁡ (𝑦−𝑝𝑚) 0.5
⁡ = ⁡ (⁡ ) = 1.002348804
𝑑𝑖 ⁡(𝑦−𝑝(𝑚+1)⁡
do = 0.905745 m
Gasket width = (do− di) / 2 = 1.06122 mm, less than 10 mm

H = 𝜋𝐺2P/4 = 0.133225 MN
Hp = πG(2b) mp = 0.002188 MN
Wo = H + Hp = 0.13541 MN
Wg = πGby = 0.067863 MN

S0 = 138 MN/m2
Am = A0= Wo / S0 = 0.0009813 m2
C2 = ID + 2(g1 + R)
flange
Table 3.36: Bolt Specifications for Flash Drum
bolt size 0.012 m

R 0.02 m
rot area 0.00006364 m2
no. of bolts 16
Bs 0.075
C1 0.0477
C1-C2 -0.9000721733
Since C1 –C2 is negative for minimum bolt size, therefore flange is not required.
3.4.3 Drawing of Equipment

Drawing of Heat Exchanger 1

Figure 3.9: Heat Exchanger Drawing
Drawing of Heat Exchanger 2

Figure 3.10: Heat Exchanger Drawing
3.4.4 Specifications and material of construction of all process equipment
Compressor C1
Table 3.37 Compressor Details
Type of Compressor Isentropic Compressor

Material Used Carbon Steel
Net Power Required(kW) 1994.7
Inlet Pressure (bar) 1.01325
Outlet Pressure (bar) 30

Compressor C2

Net Power Required (kW) 2526.3
Compressor C3

Net Power Required (kW) 1637.9
FLASH DRUM (F1)
Table 3.40 Flash Drum Details
Material of construction Carbon Steel

Diameter (m) 4.332065978
Height (m) 8.765628781
Pressure (kPa) 1000
Temperature (K) 318
FLASH DRUM (F2)
Table 3.41 Flash Drum Details

Diameter (m) 0.883622173
Height (m) 3.936093851
Pressure (kPa) 200
Temperature (K) 333
HEAT EXCHANGER (H1)

Table 3.42 Heat Exchanger Details
Material of construction Cupro-Nickel

Type Shell and Tube
No. of shell passes 1
No. of tube passes 1
Tube inner diameter (mm) 45.3
Tube outer diameter (mm) 50.8
Tube length (m) 4.88
No of tubes 100
Pitch (mm) 63.5
Shell inner diameter (mm) 808.41
Overall heat transfer coefficient (W/m2°C) 404.78
HEAT EXCHANGER (H2)

Type Shell and Tube
No of tubes 730
Pitch (mm) 31.75
HEAT EXCHANGER (H3)

Type Shell and Tube
No of tubes 160
Pitch (mm) 15.875

REACTOR (B2)
Table 3.45 Reactor Details
Pressure (bar) 30
Temperature (°C) 240
Volume (m3) 2.769
Type Plug Flow
Length (m) 3.399
Diameter (m) 1.007
Residence Time (s) 3.182
VALVE (V1)
Table 3.46 Valve Details

Inlet Pressure (bar) 10
DISTILLATION COLUMN (DISTIL)
Table 3.47 Distillation Column Details
Material of construction Carbon steel

Number of Trays 20
Feed Tray 10
Reflux ratio 5
Condenser Type Total
Reboiler Type Kettle
Top stage pressure(bar) 1.9
Distillate to feed ratio 0.46
Distillate rate (kmol/hr) 120
Number of Holes 7396
Column Diameter (m) 1.56
3.4.5 Major engineering problems and their remedies

A. Catalytic Reactors:
Problem:
• Dumped catalyst beds and downtime to reinstall the catalyst and clean downstream
equipment.

Cause:
• Inadequate design and careless installation of bed supports, particularly the wire mesh
screen support.
Remedies:
Following features should be incorporated into the catalytic reactor design:
• External insulation for heat conservation and to prevent corrosion of the vessel shell.
• Inlet flow distributors to prevent impingement of process gas directly onto catalyst
bed which can cause flow channelling and bed movement.
• Two 3" layers of active catalyst bed support balls. The lower layer should be 1/2"
diameter balls, and the upper layer 1/4" diameter balls.
• Except for very small catalyst beds, reactor should have at least 9 thermocouples
located at 25%, 50%, and 75% of bed length and depth. For very large beds, the
thermocouples should be located on no more than 8 ft. spacing. The bed
thermocouples should be monitored regularly to track any catalyst deactivation.
B. Corrosion:
Corrosion in reactor during normal operation is limited if the related piping is adequately
steam heated and properly insulated. Severe corrosion may take place if plant is insufficiently
purged.
C. Reactor Explosion:
Problems:
• Excess pressure and inappropriate material of construction.

• Methanol is dangerous when exposed to heat, flame or oxidizers, and as a
consequence, it requires adhering to the safety measures when stored or manipulated
by operators. The same precaution is valid for the raw materials.
• Hydrogen is a very flammable gas and can cause fires and explosions if it is not
handled properly.
Remedies:

• Proper pressure controller

• Good quality of material of construction
• Proper designing of the reactor
D. Boiler or Condenser Leakage:
Although these problems seldom occur, it is difficult to distinguish the symptoms. A decrease
in steam production, a lower gas outlet temperature of the boiler and a higher plant pressure
drop are the first indications. A method to determine whether there is leakage is to stop the
blowdown of boiler water and to analyse the phosphate and salt content of the boiler water. If
a leakage is identified, the plant should be stopped to prevent a crash shutdown.
E. Catalyst Deactivation
Causes:
• Sintering or Aging
• Fouling
• Excessive pressure drop across the catalyst bed
• At high temperatures catalyst sintering takes place.
• Uncontrollable variation in the feed rate causes difficulties in air/ gas ratio.
Remedies:
• Sintering of catalyst: Absolute temperature control will reduce the incidence of

sintering in the catalyst beds.
• Feed quality should be continuously monitored. Feed should be continuously checked
if unwanted impurities should be present.
Problems in Heat Exchangers
The most common heat exchanger problem for many chemical engineers is fouling which can
occur within the inside of a tube wall and decrease performance and even damage the heat
exchanger in the long run.
Fouling is a term used to describe material which builds up on the inside of a tube wall within
heat exchangers and in turn affects the performance of the heat exchanger.
Not treating fouling can lead to other major heat exchanger problems which can affect heat
transfer as well as the pressure drop within your heat exchanger.

Most common causes of fouling are:
• Settlement of sludge, rust, or dust particles

• Corrosion
Possible Remedies for fouling problem:
1) Choosing a material of construction which does not easily corrode or produce voluminous
deposits of corrosion products. If chemical removal of fouling is planned, the material
selected must also be resistant to attack by cleaning solutions.
2) Some type of fouling can be controlled and minimized by using high fluid velocities.
3) If fouling cannot be prevented from forming, it is necessary to make some provisions for
its periodic removal. Some deposits can be removed by purely chemical means. Since
chemical cleaning does not ordinarily require the removal of equipment. It is the most
convenient of cleaning techniques.
4) There are number of techniques for mechanical removal of fouling as well.
Problems in Storage Tanks
Leaking storage tanks, whether above or below ground, can pollute the environment, threaten
public health, and lead to billions of dollars in direct and indirect costs.
One main reason for storage tank failure is corrosion.
Reason for corrosion of storage tanks
Corrosion is the deterioration of a material, usually a metal that results from a chemical or
electrochemical reaction with its environment. Without implementation of appropriate
corrosion control measures, storage tanks will deteriorate. Most tanks are made of steel, a
material highly susceptible to corrosion.
Corrosion-related damage is accelerated by factors including the tank’s interaction with

interconnected components, corrosive environmental conditions, and stray electric currents.
Over time, uncontrolled corrosion can weaken or destroy components of the tank system,
resulting in holes or possible structural failure, and release of stored products into the
environment.
Possible solutions to control corrosion in storage tanks

Modern corrosion control combines historically proven methods with state-of-the-art

technology to prevent tanks from deteriorating. Corrosion-control strategies are used
individually or in combination with one another.
Common strategies include corrosion-resistant materials, application of coatings and/or

linings as a barrier to the environment, various forms of cathodic protection to prevent
deterioration of tank components in contact with the soil, and use of inhibiting chemicals in
stored substances to control corrosion of the tank interior.
3.5 Materials Storage & Handling Facilities

H2 (Hydrogen)
• Hydrogen is extremely FLAMMABLE and can be ignited by the cylinder valve being
opened to AIR and by HEAT, SPARKS and STATIC ELECTRICITY.
• Hydrogen reacts violently and explosively when mixed with OXIDIZING AGENTS
(such as PERCHLORATES, PEROXIDES, PERMANGANATES, CHLORATES,
NITRATES, CHLORINE, BROMINE and FLUORINE); ACETYLENE;
ETHYLENE; and OXYGEN.
• Hydrogen is not compatible with METALS; METAL OXIDES; and METAL SALTS.
• Store under an inert gas (such as Helium) in a cool, well-Ventilated area away from
COMBUSTIBLES and protect From temperatures above 122oF (50oC).
• Sources of ignition, such as smoking and open flames, are Prohibited where Hydrogen
is used, handled, or stored.
• Metal containers involving the transfer of Hydrogen should Be grounded and bonded.
• Use explosion-proof electrical equipment and fittings Wherever Hydrogen is used,
handled, manufactured, or Stored.
• Use only non-sparking tools and equipment, especially when Opening and closing
containers of Hydrogen.
• Hydrogen may accumulate static electricity.
• Protect cylinders from physical damage and do not drag, roll, Slide or drop

Table 3.48: Hydrogen Hazards
TYPE OF ACUTE PREVENTION FIRST AID/ FIRE

HAZARD/EXPOS FIGHTING
HAZARDS /
URE
SYMPTOMS
Fire Flammable No open flames, Stop flow of gas or use

a dry powder
No sparks, and No
extinguisher to get to
smoking.
The place where the
flow of Hydrogen can
be shut off. Allow Fire
to burn out.
Use water spray to

keep fire-exposed
containers cool.
Explosion when mixed with Protect cylinders from In case of fire: keep
OXIDIZING physical damage and drums, etc., cool by
AGENTS (such as do not drag, roll, slide spraying with water.
PERCHLORATE, or drop.
PEROXIDES,
PERMANGANAT
ES,
CHLORATES,
NITRATES,
CHLORINE,
BROMINE and
FLUORINE);
ACETYLENE;
ETHYLENE; and
OXYGEN.

Exposure
Inhalation Headache, Ventilation, local Remove the person

from exposure.
Dizziness, exhaust, or breathing
Begin rescue breathing
Drowsiness protection.
(using universal
precautions) if
breathing has stopped
and CPR if heart action
has stopped.
Transfer promptly to a
medical facility.
Skin Dry skin Wear protective Remove Contaminated

clothing made of Clothes.
material that does not
Immerse affected part
generate static
in warm water. Seek
electricity.
medical attention.
All protective clothing
(suits, gloves,
footwear, headgear)
should be clean,
available each day, and
put on before work.
Eyes Redness, Pain Wear non-vented, Immediately flush with

impact resistant large amounts of water
goggles when working for at least 30 minutes,
with fumes, gases, or lifting upper and lower
vapors. lids.
Wear a face shield Remove contact lenses,

along with goggles if worn, while flushing.

when working with Seek medical attention

corrosive, highly immediately.
irritating or toxic
substances.
Spills and leaks
If Hydrogen is leaked, take the following steps:
• Evacuate personnel and secure and control entrance to the Area.

• Eliminate ignition sources.
• Ventilate area of leak to disperse the gas.
• Stop flow of gas. If source of leak is a cylinder and the leak Cannot be stopped in
place, remove the leaking cylinder to a Safe place in the open air, and repair leak or
allow cylinder to Empty.
• Keep Hydrogen out of confined spaces, such as sewers, Because of the possibility of
an explosion.
• Use water spray to keep containers cool.
• Conduct air monitoring to determine that Oxygen levels are Above 19.5%.
• It may be necessary to contain and dispose of Hydrogen as A HAZARDOUS
WASTE. Contact state Department of Environmental Protection (DEP) or your
regional office of the Federal Environmental Protection Agency (EPA) for specific
Recommendations.
Health Hazard Information
Acute Health Effects
The following acute (short-term) health effects may occur Immediately or shortly after
exposure to Hydrogen:
• Contact with liquefied Hydrogen can cause severe burns And frostbite to the skin and
eyes.

• Very high levels of Hydrogen can decrease the amount of Oxygen in the air and cause
suffocation with symptoms of Headache, dizziness, weakness, nausea, vomiting, loss
of Coordination and judgment, increased breathing rate, loss of Consciousness and
death.
Chronic Health Effects
The following chronic (long-term) health effects can occur at Some time after exposure to
Hydrogen and can last for Months or years:
Cancer Hazard
• According to the information presently available to the New Jersey Department of

Health and Senior Services, Hydrogen has not been tested for its ability to cause
cancer In animals.
Reproductive Hazard

Health and Senior Services, Hydrogen has not been tested for its ability to affect
Reproduction.
Other Effects
No chronic (long-term) health effects are known at this time.
CO2 (CARBON DIOXIDE)
Handling and Storage
Prior to working with Carbon Dioxide, you should be trained on Its proper handling and
storage.

• Dusts of various METALS (such as MAGNESIUM, ZIRCONIUM, TITANIUM and

CHROMIUM) can ignite or explode when suspended in Carbon Dioxide
• Carbon Dioxide reacts with WATER to form Carbonic Acid.
• Carbon Dioxide is not compatible with OXIDIZING AGENTS (such as
PERCHLORATES, PEROXIDES, PERMANGANATES, CHLORATES,
NITRATES, CHLORINE, BROMINE and FLUORINE); REDUCING AGENTS
(such as LITHIUM, SODIUM, ALUMINUM and Their HYDRIDES); METAL
CARBIDES; METAL SALTS; and STRONG BASES (such as SODIUM
HYDROXIDE and POTASSIUM HYDROXIDE).
• Store in tightly closed containers in a cool, well-ventilated Area away from
COMBUSTIBLE MATERIALS.
• Carbon Dioxide may accumulate static electricity, even When being filled into
properly grounded containers.
Spills and leaks
If Carbon Dioxide is leaked, take the following steps:

• Evacuate personnel and secure and control entrance to the Area.
• Eliminate ignition sources.
• Ventilate area of leak to disperse the gas.
• Stop flow of gas. If source of leak is a cylinder and the leak Cannot be stopped in
place, remove the leaking cylinder to a Safe place in the open air, and repair leak or
allow cylinder to Empty.
• Gas is heavier than air and may accumulate in low ceiling Spaces and confined
spaces.
• It may be necessary to contain and dispose of Carbon Dioxide as a HAZARDOUS
WASTE. Contact your state Department of Environmental Protection (DEP) or your
regional office of the federal Environmental Protection Agency (EPA) for specific
recommendations.
Table 3.49: Carbon dioxide hazards

HAZARD/EXPOS HAZARDS
FIGHTING
URE /SYMPTOMS
MEASURES
Fire Flammable No open flames,No Extinguish fire using an
sparks, and No agent suitable for type of
smoking.

surrounding fire. Carbon

Dioxide itself does not
burn.
Use water spray to keep
fire-exposed containers
cool.
Explosion CONTAINERS Closed In case of fire: keep
MAY system,ventilation, drums, etc., cool by
EXPLODE IN explosion-proof spraying with water.
FIRE. electrical equipment
and lighting.
Flow or
agitation may Use Non-sparking
generate Handtools.
electrostatic
charges and
May ignite any
explosive
mixtures
present.
Exposure
Inhalation Cough, Ventilation, local Remove the person from
exhaust, or breathing exposure.
Dizziness,
protection
Begin rescue breathing
Drowsiness,
(using universal
Headache
precautions) if breathing
Nausea.
has stopped and CPR if
heart action has stopped.
medical facility.
Skin Dry skin All protective Quickly remove
clothing (suits, contaminated clothing.
gloves, footwear, Immediately wash
headgear) should be contaminated skin with
clean, available each large amounts of water.
day, and put on
before work.

Where exposure to Immerse affected part in

cold equipment, warm water. Seek medical
vapors, or liquid may attention.
occur,
employees should be
provided with
insulated gloves and
special clothing
designed to prevent
the freezing of body
tissues.
Eyes Redness,Pain. Wear non-vented, Immediately flush with
impact resistant large amounts of water for
goggles when at least 15 minutes, lifting
working with upper and lower lids.
fumes,gases, or
Remove contact lenses, if
vapors.
worn, while flushing. Seek
If additional medical attention.
protection is needed
for the entire face,
use in combination
with a face shield. A
face shield should not
be used without
another type of eye
protection.
The following acute (short-term) health effects may occur Immediately or shortly after
exposure to Carbon Dioxide:
• Contact can irritate and burn the skin and eyes. Direct Contact with the liquid or solid
(“dry ice”) can cause frostbite.

• Exposure to Carbon Dioxide can cause headache, Dizziness, difficulty breathing,

tremors, confusion and ringing In the ears. Higher exposure can cause convulsions,
coma And death.

The following chronic (long-term) health effects can occur at Some time after exposure to
Carbon Dioxide and can last for Months or years:
Cancer Hazard
Health, Carbon Dioxide has not been Tested for its ability to cause cancer in animals.
Reproductive Hazard
• There is limited evidence that Carbon Dioxide causes Spontaneous abortions.
Medical
Medical Testing
If symptoms develop or overexposure is suspected, the Following is are recommended:
• Evaluate for brain effects such as changes in memory, Concentration, sleeping
patterns and mood (especially Irritability and social withdrawal), as well as for
headaches and fatigue.
• Exam of the eyes and vision
CH3OH (METHANOL)
Handling and Storage
• Methyl Alcohol reacts violently or explosively with OXIDIZING AGENTS (such as

PERCHLORATES, PEROXIDES, PERMANGANATES, CHLORATES,
NITRATES, CHLORINE, BROMINE and FLUORINE); ALKYL ALUMINUM

SALTS; ACETYL BROMIDE; CHROMIC ANHYDRIDE; MIXTURES of

CHLOROFORM and SODIUM HYDROXIDE; PHOSPHORUS TRIOXIDE;
MIXTURES of SULFURIC ACID and HYDROGEN PEROXIDE; ISOCYANATES;
METALS (such as LEAD, MAGNESIUM and POTASSIUM); and NITRIC ACID.
• Methyl Alcohol attacks some PLASTICS, RUBBERS and COATINGS.
• Store in tightly closed containers in a cool, well-ventilated area away from HEAT
SOURCES.
• Sources of ignition, such as smoking and open flames, are prohibited where Methyl
Alcohol is used, handled, or stored.
• Metal containers involving the transfer of Methyl Alcohol should be grounded and
bonded.
• Use explosion-proof electrical equipment and fittings wherever Methyl Alcohol is
used, handled, manufactured, or stored.
• Use only non-sparking tools and equipment, especially when opening and closing
containers of Methyl Alcohol.
Table 3.50: Methanol Hazards

HAZARD/EXPOS HAZARDS
FIGHTING
URE /SYMPTOMS
MEASURES
Fire Flammable No open flames, No Use dry chemical,

sparks, and No CO2, water spray or
smoking.
alcohol-resistant foam
as extinguishing
agent.
Water may not be

effective in fighting
fires

Use water spray to

keep fire-exposed
containers cool.
Explosion CONTAINERS Closed In case of fire: keep

MAY system,ventilation, drums, etc., cool by
EXPLODE IN explosion-proof spraying with water.

FIRE. electrical equipment
and lighting.
Use Non-sparking
Handtools.
Exposure
Inhalation Cough, Ventilation, local Remove the person

exhaust, or breathing from exposure.
Dizziness,
protection
Begin rescue
Drowsiness,
breathing (using
Headache universal
Nausea.
precautions) if
breathing has stopped
and CPR if heart
action has stopped.
medical facility.
Skin Dry skin All protective clothing Quickly remove

(suits, gloves, contaminated
footwear, headgear) clothing. Immediately
should be clean, wash contaminated

available each day, and skin with large

put on before work. amounts of water.
Where exposure to Immerse affected part

cold equipment, in warm water. Seek
vapors, or liquid may medical attention.
occur,
employees should be
provided with
insulated gloves and
special clothing
designed to prevent the
freezing of body
tissues.
Eyes Redness,Pain. Wear non-vented, Immediately flush

impact resistant with large amounts of
goggles when working water for at least 15
with fumes,gases, or minutes, lifting upper
vapors. and lower lids.
If additional protection Remove contact

is needed for the entire lenses, if worn, while
face, use in flushing. Seek medical
combination with a attention.
face shield. A face
shield should not be
used without another
type of eye protection.
Spills and Leaks
If Methyl Alcohol is spilled or leaked, take the following steps:

• Evacuate personnel and secure and control entrance to the area.

• Eliminate all ignition sources.
• Absorb liquids in dry sand, earth, or a similar material and place into sealed
containers for disposal.
• Ventilate area of spill or leak.
• Keep Methyl Alcohol out of confined spaces, such as sewers, because of the
possibility of an explosion.
• It may be necessary to contain and dispose of Methyl Alcohol as a HAZARDOUS
WASTE. Contact your state Department of Environmental Protection (DEP) or your
regional office of the federal Environmental Protection Agency (EPA) for specific
recommendations.

The following acute (short-term) health effects may occur immediately or shortly after
exposure to Methyl Alcohol:
• Contact can cause skin irritation.

• Methyl Alcohol can irritate the eyes and can cause blurred vision and blindness.
• Inhaling Methyl Alcohol can irritate the nose, throat and lungs causing coughing,
wheezing and/or shortness of breath.
• Methyl Alcohol can cause nausea, vomiting, diarrhoea and abdominal pain.
• Exposure to high concentrations can cause headache, dizziness, drowsiness, fatigue,
loss of consciousness and death.
The following chronic (long-term) health effects can occur at some time after exposure to
Methyl Alcohol and can last for months or years:
Cancer Hazard
• There is no evidence that Methyl Alcohol causes cancer in animals. This is based on
test results presently available to the NJDHSS from published studies.

Reproductive Hazard
• Methyl Alcohol may be a TERATOGEN in humans since it is a teratogen in animals.
Other Effects
• Prolonged or repeated contact can cause a skin rash, dryness, redness and cracking of
the skin.
• Methyl Alcohol may damage the liver, kidneys and nervous system.
3.6 Process Instrumentation & Control and Safety Aspects

ABSTRACT
The many control systems that the plant requires have been outlined. Equipment for
measuring temperature, level, and flow has also been provided. There is also a list of all the
control systems that are employed in the equipment. A detailed control system for critical
equipment has been specified for the plant design.
3.6.1 INTRODUCTION
The primary goal of every operation or process is to generate a specified product that meets a
set of quality and specification requirements. Two critical instruments for monitoring this
need are quality control and the right implementation of efficient process instrumentation and
control systems in the plant. The values of variables such as temperature, pressure, density,
viscosity, specific heat, conductivity, pH, humidity, dew point, liquid level, and flow rate can
be constantly recorded and regulated within precise limits using equipment of increasing
degrees of complexity.
The economic function of any operation is aided by process instrumentation and control,
which maintains, improves, and controls numerous process parameters such as flow rates,
temperature, pressure, level, composition, and so on. A well-controlled process plant system
also ensures improved operational safety. The parameter could be measured directly or
indirectly. In the task of monitoring and managing process parameters, empirical relations are
derived and followed.

The greater expenditure in instrumentation and control systems must be justified. Process
control must help the plant run smoothly and provide enough returns in terms of increased
productivity, quality, and stability of the various processes, as well as in achieving the desired
goals.
Instrumentation and control systems must justify the additional investment in them. Process
control must aid the smooth operation of the plant and show adequate returns in terms of
greater productivity, quality and stability of the various processes and in producing the
desired results.
With respect to our plant, controls for the following variables may be required:
1. Pressure
Pressure measurement systems including inductive, capacitive, and piezo-electric gauge,
absolute and differential pressure; calibration of gauges; selection criteria and specifications.
ISA symbols and case study.
2. Level
Level measurement systems including resistance, capacitance, radiation and optical methods.
selection criteria and specification; ISA symbols and case study.
3. Temperature
Temperature measurement systems including platinum resistance, thermistors,
thermocouples.
pyrometers; selection criteria and specifications; ISA symbols and case study.
4. Density and Flow

Flow measurement systems including venturi tube, orifice plate, magnetic flow meter, vortex
meter, ultrasonic flow meter, Pitot-static tube, Coriolis meter, mass flow meters; density
measurement systems including vibrating element and radiological devices; selection criteria
and specifications; ISA symbols and case study.
Following are described various sensors available for controlling these parameters:

3.6.2 TEMPERATURE MEASUREMENT
Temperature is the most measured metric. Accurate temperature measurement is crucial for
success in industrial applications such as the process industry and laboratory environments.
Temperature measurement is an important aspect of instrumentation in the petrochemical
industry.
There are mainly two devices that are most widely used for temperature measurement:
1. Resistance Temperature Indicators (RTD's)
2. Thermocouple
RTDs
Resistance Thermometers, or Resistive Thermal Devices, are other names for RTDs. RTDs
(Resistance Temperature Detectors) are wire wound and thin film devices that use the
physical principle of the positive temperature coefficient of electrical resistance in metals to
measure temperature. The larger or higher the value of their electrical resistance, the hotter
they grow.
In an RTD, the resistance of the device is proportional to temperature. The most common
resistive material for RTDs is platinum, with some RTDs being made from nickel or copper.
RTDs have a wide range of temperatures. Depending on their construction, they can measure
temperatures in the range of –270 to +850 degrees C.
There are many RTD categories; Carbon Resistors, Film Thermometers, and Wire-Wound
types are the most widely used.
Carbon Resistors are widely available and are very inexpensive. They have very reproducible
results at low temperatures. They are the most reliable form at extremely low temperatures.
They generally do not suffer from hysteresis or strain gauge effects. Carbon resistors have
been employed by researchers for years because of the many advantages associated with
them.
Film Thermometers have a layer of platinum on a substrate; the layer may be extremely thin,

perhaps one micrometer. Advantages of this type are relatively low cost and fast response.
Such devices have improved performance although the different expansion rates of the
substrate and platinum give “strain gauge” effects and stability problems.
Advantages and Disadvantages
RTDs have some distinct advantages over other temperature-measuring devices. For one,
they are the most stable and most accurate of all the different devices. Plus, they are more
linear than thermocouples.
There are a few drawbacks, however.
RTDs are more expensive than thermistors and thermocouples. Also, they require a current
source. They have a small ∆R, which means there is a low resistance to temperature change.
For example, to change one degree C, the RTD might change by 0.1Ω.
However, low absolute resistance could lead to measurement errors if using the two wire
method, and there is the self-heating that needs to be compensated.
When using RTDs, there are several common mistakes that are often unaccounted for, the
the biggest of which is self-heating.
If the RTD self-heats with the test current, this could lead to measurement inaccuracy.
If measuring low temperature (e.g., below 0°C), the heat from the RTD could raise the
expected temperature. Also, if the test leads are not compensated for, then even more errors
could be introduced into the measurement.
THERMOCOUPLE
Thermocouple is a device consisting of two different conductors, which is usually metal

alloys that produce a voltage, proportional to a temperature difference, between either ends of
the two conductors.
They are based on the principle that two wires made of dissimilar materials connected at
either end will generate a potential between the two ends that is a function of the materials
and temperature difference between the two ends (also called the Seebeck Effect).

The joined end is referred to as the HOT JUNCTION. The other end of these dissimilar
metals is referred to as the COLD END or COLD JUNCTION. The cold junction is actually
formed at the last point of thermocouple material.
Advantages:
it is rugged in construction
Covers a wide temperature range
Using extension leads and compensating cables, long transmission distances for
temperature measurement possible. This is most suitable for temperature measurement of
industrial furnaces Comparatively cheaper in cost Calibration can be easily checked
Offers good reproducibility High speed of response Satisfactory measurement accuracy
Limitations:
For accurate temperature measurements, cold junction compensation is necessary
The EMF induced versus temperature characteristics is somewhat nonlinear
Stray voltage pickup is possible
In many applications, amplification of signal is required.
3.6.3 LEVEL MEASURING INSTRUMENTS
There are two methods used to measure the level of a liquid:

1) Direct Methods
2) Indirect or inferential Methods.
A. DIRECT METHODS
Direct methods are simple and reliable. Direct methods for level measurement are mainly
used
where level changes are small and slow such as Sump tanks and Bulk storage tanks.
1. DIPSTICK

The simple dipstick is a calibrated metal bar or rod mounted vertically in a fixed position.
The dipstick is removed and the mark left by the liquid enables the liquid level to be read. It
does not provide continuous readings. Dipsticks are used for checking the oil level in engine
sumps and in the determination of liquid levels in tanks.
2. GAUGE GLASSES
GAUGE GLASSES are devices used to provide a visual indication of a liquid level that
consist
of a glass tube connected above and below the liquid level in a tank that allows the liquid
level
to be observed visually. GAUGE GLASSES are used as a visual indication right at the tank
location. As the level of the tank increases or decreases, the liquid level is observed inside the
glass tube. The liquid level is the same as the level inside the tank.
3. FLOATS
Level devices using Floats are dependent on the buoyancy of an object to measure level. A
a floating object determines the surface of a liquid, whereas a solid object lowered down to
top of material in a silo determines the level of that product.
A Float is a point level measuring instrument consisting of a hollow ball that floats on top of
a liquid in a tank. Floats are attached to the instrument by a lever to an on/off Switch
activated by the movement of the float.
B. INDIRECT METHODS:
The indirect or inferential method of measurement uses the changing position of the liquid
surface to determine level with reference to a datum line. It can be used for low & high levels
where the use of the direct method instruments is impractical.
Hydrostatic Pressure Methods

Displacement devices

Capacitance Level Instrumentation
1. HYDROSTATIC PRESSURE METHODS
A vertical column of fluid exerts a pressure due to the column’s weight. The relationship
between column height and fluid pressure at the bottom of the column is constant for any
particular fluid (density) regardless of vessel width or shape. This principle makes it possible
to infer the height of liquid in a vessel by measuring the pressure generated at the bottom:
P=pgh P= γh
Where,
P = Hydrostatic pressure
ρ = Mass density of fluid in kilograms per cubic meter
g = Acceleration of gravity
γ = Weight density of fluid in newton per cubic meter
h = Height of vertical fluid column above point of pressure measurement
2. DISPLACEMENT DEVICES
The displacement level transmitter is commonly used for continuous level measurement. It
works on the buoyancy principle.
The displacer has a cylindrical shape therefore each increment of submersion in the liquid; an
equal increment of buoyancy change will result. This is a linear and proportional relationship.
When the weight of an object is heavier than an equal volume of the fluid into which it is
submerged, full immersion results and the object never floats. Although the object (displacer)
never floats on the liquid surface, it does assume a relative position in the liquid. As the
liquid level moves up and down along the length of the displacer, the displacer undergoes a
change in its weight caused by the buoyancy of the liquid. Buoyancy is explained by
Archimedes' principle, which states that: "The resultant pressure of a fluid on a body
immersed in it acts vertically upward through the center of gravity of the displaced fluid and
is equal to the weight of the fluid displaced". The upward pressure acting on the area of the
displacer creates the force called buoyancy.

The immersed displacer is supported by arms or springs that allow some small amount of
vertical movement or displacement of the displacer due to buoyancy forces caused by the
change in the liquid level. This buoyancy force can be measured to reflect the level
variations.
When a body is fully or partially immersed in any liquid, it is reduced in weight by an
amount
equal to the weight of the volume of liquid displaced.
3. CAPACITANCE LEVEL INSTRUMENTATION

A capacitor consists of two conductors (plates) that are electrically isolated from one another
by a non-conductor (dielectric). When the two conductors are at different potentials
(voltages), the system can store an electric charge. The storage capability of a capacitor is
measured in farads. The capacitor plates have an area (A) and are separated by a gap (D)
filled with a no conducting material of dielectric constant (K).
C=KA/D
Capacitance (C) is calculated as:

If the area (A) and the distance (D) between the plates of a capacitor remain constant,
capacitance will vary only as a function of the dielectric constant of the substance filling the
gap between the plates.
3.6.4. FLOW MEASUREMENT
Flow meter is a device that measures the rate of flow or quantity of a moving fluid in an open
or closed conduit. Flow measuring devices are generally classified into five groups.
1. Differential Pressure meters: Fixed restriction variable head type flow meters using
different sensors like orifice plate, venturi tube, flow nozzle, pitot tube and dall tube.
2. Mechanical type flow meters: Quantity meters like positive displacement meters etc.
3. Inferential type flow meters: Variable area flow meters (Rotameters), turbine flow meter,
target flow meters etc.
4. Electrical type flow meters: Electromagnetic flow meter, Ultrasonic flow meter, mass flow
meters, Laser Doppler Anemometers etc.

5. Other flow meters: Purge flow regulators, Flow meters for Solids flow measurement,
Cross- correlation flow meter, Vortex shedding flow meters, flow switches etc.
3.6.5 TYPE OF CONTROL SYSTEMS AND THEIR USES WITH RESPECT TO

THIS
PLANT
A control system is ideally designed to fulfil the following demands:
1) Durability
2) Short time lag
3) Flexibility
4) Repeat performances
5) Self-alarm or indicating systems
6) Dead band
7) Compactness and portability
8) Ease of installation
9) Automation, precision, accuracy and high resolution
10) High sensitivity
Types of Control System
Pneumatic Type
It is based on the flow of the compressed air. The flow of air actuates the diaphragm valves
resulting in change in flow conditions. Though commonly used in India until now, it is being
increasingly replaced by the electronically operated controls.
Electronic controllers
It uses digital distributed control system, single loop microprocessor controllers with display
units and computerized control.

COMPARISON
1) Electronic instruments are more accurate as it is easier to read in a digital voltmeter than
on the meniscus of a mercury column.
2) Sensitivity: It is defined as the smallest change applied to the transmitter – transducer
that will produce a measurable movement at the final operator. It is same in both the
cases.
3) Speed of response: Electronic instruments are always faster with a time constant in micro
seconds.
4) Frequency response curve of electronic instruments are flat up to 30 Hz whereas that of
pneumatic controllers are flat up to only 10 Hz. In electronic control, the signal to and
from the controllers is instantaneous.
5) Flexibility: Pneumatic controls can be controlled to an unlimited number of receivers.
One controller can control many valves. Electronic equipment also had almost the same
flexibility and one may connect main pieces of output signal to the same output signal. If
measurement signals are transmitted to control room for display, automation control or
Computation, scanning and high speed data logging are done more easily. Pneumatic
operator provides a large driving force and sufficient response speed. So they serve
better than electronics actuators.
6) Freedom from critical operating failures is aspect of reliability: Critical failure could be
loss of compressor in a pneumatic system or loss of central power in an electronic system.
Reliability is of the same standard in both.
7) Safety: Though electronic ones are better otherwise, they are prone to fire hazards and
explosive atmosphere. In such cases pneumatic controls are preferred.
8) Cost: for electronic systems, cost is about 30% higher than that for a comparable
pneumatic system.
Thus, though little costly, electronic controls are much more efficient than pneumatic
controls. New plants are going in for electronic systems mainly and the older ones are also
switching over to this.
3.6.6 DISTRIBUTED SYSTEM FOR PROCESS CONTROL
Earlier, plants were constructed with a distributed system in the sense that the individual

controllers were located near the process equipment with which interacted. To control and
adjust the operating parameter, operator had to go to each area consuming unnecessary
resources. So, controllers were then started to be maintained in a single room so that operator
could quickly assess the status of the process and make adjustments. The remote multiplexer
is being further used. This unit consists of a minicomputer and microprocessor. The process
signals are scanned, converted to digital and transmitted to central computer located adjacent
to the control room. So a single path is shared for all of these processes as against an
individual signal path for each process.
Based on the above mentioned parameters, automatic control has generally been accepted
throughout the chemical industry. The resultant savings in labour combined with improved
ease and efficiency of operations has more than offset the added expense for instrumentation.
We have also used high speed computers as they serve vital tools in the operation of the
plant. Effective utilization of the instruments that we have employed in our plant is achieved
by centralized control, whereby one centrally located control room is used for the indication,
recording and regulation of the process variables. Panel boards have been developed which
present a graphical representation of the process and have the instrument controls and
indicators mounted at the appropriate locations in the overall process. This helps a new
operator to quickly become familiar with the significance of the instrument reading and rapid
location of any operational variance is possible. We have planned to design the control
system correctly so that the problems of transmission lags, cycling due to slow or
uncompensated response, radiation errors, or similar factors are tackled easily.
A regular procedure of noting down the readings from the controllers after fixed intervals of
time would be inculcated among the operators, so that very high quality standards can be
developed.
The primary objectives of the designer when specifying instrumentation and control schemes
are:
1.Safe plant Operation:
To keep the process variables within known safe operating limits.

To detect dangerous situations as they develop and to provide alarms and
automatic shutdown systems.
To provide interlocks and alarms to prevent dangerous operating procedures.

2.Production rate: To achieve the design product output.

3.Product quality: To maintain the product composition with the specified quality standards.
4.Cost: To operate the lowest production cost, commensurate with the other objectives.
Desirable features of a control system: Several characteristics of control system have been
mentioned and now need to be defined. A good control system should be-
A good servo: It should track set points quickly and smoothly.
A good regulator: It should reject all disturbances (major and minor) efficiently
Robust: It should not be sensitive to changes in operating conditions
Graceful: It should handle constraints on both the input variables and the output
variables
1. Control System for Heat Exchangers
Figure 3.11: Heat Exchanger with temperature control
The above figure (a) shows a heat exchanger where the flow of cooling water is adjusted
based on the temperature of the outlet stream. The advantage to this setup is that it is quite
straightforward and the cause of the change in the temperature of the outlet stream does not

have to be identified. The disadvantage is that a temperature change has already occurred
before action is taken, and if the lag-time for the additional cooling water to cool the process
stream is long, the outlet stream temperature may be inconsistent.
The above figure (b) shows a heat exchanger where the flow of cooling water is adjusted
based on the flowrate and temperature of the inlet stream and the temperature of the coolant
stream. Based on a set of calculations using the heat transfer coefficient of the heat
exchanger, the outlet stream temperature can be predicted. The advantage of this system is
that action is taken before changes occur in the outlet stream temperature. The disadvantage
is that if the actual heat exchange capacity differs from the expected value due to fouling or
mechanical problems, the outlet temperature will not be correct.
2. Control System for Distillation Column
The effective operation of a binary distillation column is determined by the control of many
variables. The two main disturbances that affect a column are:
feed flow rate, F
feed composition
So called 'manipulated variables' are adjusted to counteract the effect of disturbances and
ensure desired operation.
A ‘bottom – up’ approach should be adopted whereby variables that are essential to operation
are regulated before quality variables. In other words, pressure and then level must be
adequately controlled before attention is focused on control of composition
Pressure Control
Here, pressure is regulated using the flowrate of coolant to the condenser. Increasing or
decreasing the water flow rate will alter the temperature of the condensing liquid and hence
the amount of vapor in the column. This, in turn, alters the pressure in the column. This will
be a slow loop as the dynamics effects of the cooling can be slow in comparison to simply
venting the system by e.g., opening a valve.

Figure 3.12: Common Pressure Control Loop
Level Control
There will be two level loops on a distillation column as:

The column base level must be maintained at an acceptable value.
The reflux drum level must be maintained at an acceptable value.
There are actually only 3 schemes that offer acceptable input-output combinations (from a
practical viewpoint).
Scheme (I)
Control level in the column base via manipulation of the bottom product flow rate (by
automatically adjusting value).
Control level in the reflux drum by manipulation of distillate flow rate.
A flow controller has been placed on the reflux line (to ensure steady flow of reflux to
the column).

Figure 3.1: Level Control
Scheme (II)
Control level in the column base by manipulation of the vapor boil-up through the
energy input to the reboiler (in practice this is achieved by automatically adjusting the
pressure/ flow of the heating medium to the reboiler).
Control level in the reflux drum by manipulation of distillate flow rate.
A flow controller has been placed on the reflux line (to ensure steady flow of reflux to
the column).

Scheme (III)
Control level in the column base by manipulation of bottoms flow rate.
Control level in the reflux drum by manipulation of reflux flow rate.
A flow controller has been placed on the distillate line (to ensure steady flow of product).
Composition control
On-line analysers are rarely used as the installed cost will normally be in the range of £100 K
per instrument. Therefore, composition is often regulated indirectly using temperature (at
constant pressure there is a direct relationship between temperature and composition for a
binary mixture).

Using a liquid temperature near the base of the column for bottom composition and a liquid
temperature near the top of the column for top product composition, the remaining mv’s (i.e.
those not used for the purposes of level and pressure control) may be used to regulate
composition.
4. Environmental Protection & Energy Conservation

4.1 Environmental Aspect
4.1.1 Air Pollution
Air pollution refers to the release of pollutants into the air—pollutants which are detrimental
to human health and the planet as a whole. According to the World Health Organization
(WHO), each year air pollution is responsible for nearly seven million deaths around the
globe. Nine out of ten human beings currently breathe air that exceeds the WHO’s guideline
limits for pollutants, with those living in low- and middle-income countries suffering the
most.
There are many harmful chemicals released in the air by chemical industries like carbon
dioxide, carbon monoxide, hydrocarbons, sulphur dioxide, nitrites, etc.
Some major air pollutants in the manufacture of methanol:

1) Carbon Dioxide:
Carbon dioxide pollution, better known as CO2 emissions, primarily comes from the burning
of fossil fuels. Two great examples of this are the consumption of gasoline in gas-powered
vehicles and the production of electricity by power plants. Carbon dioxide is a major
greenhouse gas which contributes significantly to global warming.
2) Hydrogen:
Emissions of hydrogen lead to increased burdens of methane and ozone and hence to an
increase in global warming. Therefore, hydrogen can be considered as an indirect greenhouse
gas with the potential to increase global warming.
3) Carbon Monoxide:

Carbon monoxide (CO) is a colourless, odourless, tasteless, and toxic air pollutant which is
produced in the incomplete combustion of carbon-containing fuels, such as gasoline, natural
gas, oil, coal, and wood
The Health and Environment Effects of these gases:
1) Global Warming:
Global warming, also known as climate change is caused by a blanket of pollution
that traps heat around the earth. Carbon dioxide traps radiation at ground level,
creating ground level ozone. This atmospheric layer prevents the earth from
cooling at night. One result is a warming of ocean waters. Oceans absorb carbon
dioxide from the atmosphere. However, higher water temperature compromises the
oceans’ ability to absorb carbon dioxide. Over time, the effects of carbon dioxide
are compounded.
2) Respiratory Health Hazards:

Carbon monoxide poisoning occurs when carbon monoxide builds up in your bloodstream.
When too much carbon monoxide is in the air, your body replaces the oxygen in your red
blood cells with carbon monoxide. This can lead to serious tissue damage, or even death.
Signs and symptoms of carbon monoxide poisoning may include:
• Dull headache
• Weakness
• Dizziness
• Nausea or vomiting
• Shortness of breath
• Confusion
• Blurred vision
• Loss of consciousness
Carbon monoxide poisoning can be particularly dangerous for people who are sleeping or
intoxicated. People may have irreversible brain damage or even die before anyone realizes
there's a problem.

Respiratory failure is a serious condition that develops when the lungs can’t get enough
oxygen into the blood. Build-up of carbon dioxide can also damage the tissues and organs
and further impair oxygen. A high carbon dioxide level can cause rapid breathing and
confusion. Some people who have respiratory failure may become very sleepy or lose
consciousness. They also may have arrhythmia (irregular heartbeat). You may have these
symptoms if your brain and heart are not getting enough oxygen. Other symptoms of
exposure to too much CO2 include: headaches, dizziness, restlessness, a tingling or pins or
needles feeling, difficulty breathing, sweating, tiredness, increased heart rate, elevated blood
pressure, coma, asphyxia, and convulsions.
Treatment Methods:
Measures that can be taken to control Emissions are divided into two categories:
I. Treatment of Particulate Matter Emissions:
1) Electrostatic Precipitation:
High voltage electrostatic precipitators (ESPs) have been widely used throughout the world
for particulate removal since they were perfected by Fredrick Cottrell early in the twentieth
century. Most of the original units were used for recovery of process materials, but today gas
cleaning for air pollution control is often the main reason for their installation. The ESP has
distinct advantages over other aerosol collection devices:
(1) it can operate with high temperature gases, which makes it a likely choice for boilers,
steel furnaces, etc.
(2) it has an extremely small pressure drop, so that fan costs are minimized.
(3) it has an extremely high collection efficiency if operated properly on selected
aerosols (many cases are on record, however, in which relatively low efficiencies
were obtained because of unique or unknown dust properties).
(4) it can handle a wide range of particulate sizes and dust concentrations (most precipitators
work best on particles smaller than 10 mm, so that an inertial precleaner is often used to
remove the large particles).
(5) if it is properly designed and constructed, its operating and maintenance costs are lower
than those of any other type of particulate collection system. In an ESP, the particles move
through advection with the gas stream, which is travelling horizontally Through the ESP unit.
The particles become charged and then are attracted by the charge differential to either side,

where they are captured.
2) Filtration:
A filter removes particles from the carrying gas stream because the
particulate impinges on and then adheres to the filter material. With time, PM
deposits increase, and the deposit material then acts as a filtering medium. When
the deposit becomes sufficiently thick that the pressure necessary to force the gas
through the filter becomes excessive, or the flow reduction severely impairs the
process, the filter must either be replaced or cleaned.
3) Inertial Collectors:
Inertial collectors, whether cyclones, baffles, louvers, or rotating impellers, operate on the
principle that the aerosol material in the carrying the gas stream has a greater inertia than the
gas. Since the drag forces on the particle are a function of the diameter squared and the
inertial forces are a function of the diameter cubed, it follows that as the particle diameter
increases, the inertial (removal) force becomes relatively greater. Inertial collectors,
therefore, are most efficient for larger particles. The inertia is also a function of the mass of
the particle,
so that heavier particles are more efficiently removed by inertial collectors. These facts
explain why an inertial collector will be highly efficient for removal of 10- mm rock dust and
very inefficient for 5-mm wood particles. It would be very efficient, though, for 75-mm wood
particles.
4) Scrubbers:
Scrubbers, or wet collectors, have been used as gas cleaning devices for many years.
However, the process has two distinct mechanisms that result in the removal of the aerosol
from the gas stream. The first mechanism involves wetting the particle by the scrubbing
liquid. This process is essentially the same whether the system uses a spray to atomize the
scrubbing liquid or a diffuser to break the gas into small bubbles. In either case, it is assumed
that the particle is trapped when it travels from the supporting gaseous medium across the
interface to the liquid scrubbing medium. Some relative motion is necessary for the particle
and liquid–gas interface to come in contact. In the spray chamber, this motion is provided by
spraying the droplets through the gas so that they impinge on and make contact with the

particles. In the bubbler, inertial forces and severe turbulence achieve this contact. In either
case, the smaller the droplet or bubble, the greater the collection efficiency. In the scrubber,
the smaller the droplet, the greater the surface area for a given weight of liquid and the
greater the chance for wetting the particles. In a bubbler, smaller bubbles mean not only that
more interface area is available but also that the particles have a shorter distance to travel
before reaching an interface where they can be wetted.
II . Treatment of emissions of Gaseous contaminants
1. Absorption Devices:
Absorption of pollutant gases is accomplished by using a selective liquid in a wet scrubber,
packed tower, or bubble tower. Pollutant gases commonly controlled by absorption include
sulfur dioxide, hydrogen sulfide, hydrogen chloride, chlorine, ammonia, oxides of nitrogen,
and low boiling Hydrocarbons.
In our plant we are recycling CO2 through recycle stream to manufacture MeOH instead of
releasing it the air thus making our plant sustainable and carbon neutral.
2. Adsorption Devices:
Adsorption of pollutant gases occurs when certain gases are selectively retained on the
surface or in the pores or interstices of prepared solids. The process may be strictly a surface
phenomenon with only molecular forces involved, or it may be combined with a chemical
reaction occurring at the surface once the gas and adsorbed are in intimate contact. The latter
type of adsorption is known as chemisorption
3. Condensers:
In many situations, the most desirable control of vapor-type discharges can be accomplished
by condensation. Condensers may also be used ahead of other air pollution control equipment
to remove condensable components.
The reasons for using condensers include
(1) Recovery of economically valuable products
(2) Removal of components that might be corrosive or damaging to other portions
of the system
(3) Reduction of the volume of the effluent gases.

Although condensation can be accomplished either by reducing the temperature or

by increasing the pressure, in gas removal practice, it is usually done by temperature
reduction only.
4. Biological Control Systems:

Waste streams with low to moderate concentrations of VOCs may be treated with biological
systems. These are similar to biological systems used to treat wastewater, classified into three
basic types:
(1) bio filters
(2) bio trickling filters
(3) bio scrubbers.
Biofilms of microorganisms (bacteria and fungi) are grown on porous media in bio filters and
bio trickling systems. The air or other gas containing the VOCs is passed through the
biologically active media, where the microbes break down the compounds to simpler
compounds, eventually to carbon dioxide (if aerobic), methane (if anaerobic), and water. The
major difference between bio filtration and trickling systems is how the liquid interfaces with
the microbes. The liquid phase is stationary in a bio filter, but liquids move through the
porous media of a bio trickling system.
4.1.2 Liquid Effluents

ABSTRACT
In this part, we look at the sources of water contamination caused by effluent discharge and
offer preventative tips. Finally, we look at the current Liquid Effluent Discharge rules.
INTRODUCTION
Water pollution is described as the presence of solid, liquid, or gaseous pollutants in

concentrations that have the potential to degrade water quality. It may also be described as
the adding of an excessive amount of material or heat to water that is hazardous to live
organisms or hampers water's useful utilization.
Water pollution has an impact on the plants and animals that live in these bodies of water.
The result is virtually always harmful to not only individual species and populations, but also
natural ecological communities.

Water pollution is a serious worldwide issue that necessitates continuous assessment and
reform of water resource policies at all levels (international down to individual aquifers and
wells). It has been suggested that it is the largest cause of fatalities and diseases in the world,
with more than 14,000 people dying every day. Every day, an estimated 580 persons in India
die as a result of water pollution.
POSSIBLE SOURCES
The major sources of water pollution in our industry are:
1. Drains: Living creatures are harmed when hot water is discharged into rivers or other
places where infiltration may occur.
2. Spills or leakages: Any component spills or leaks. As a result, water cleaning treatment
should be performed as soon as possible following a spill. If there is a substantial amount of
leakage, absorbent paper is utilized to absorb the spill, and subsequently, water cleansing is
performed.
3. Metals: Metals can be found in effluents due to the usage of catalysts, such as Ni. Metals
must usually be removed separately since they cannot be effectively removed in biological
treatment plants.
Wastewater Prevention Techniques
1. General prevention techniques: Before contemplating wastewater treatment procedures, all

options for avoiding, reducing, and reusing wastewater must be properly explored. However,
water use, effluent generation, and effluent treatment are all intrinsically linked and should be
considered in combination. A typical exercise in preventing wastewater may include the
following steps:
Step 1: Identify wastewaters - The first stage is to identify and describe all wastewater
sources generated by a process, including their quality, quantity, and variability. An
examination can help determine which sources utilize the most water and produce the most
affluent. The production of designs that illustrate all drain networks, points of originating,
isolation valves, manholes, and sites of discharge provides further explanation.

Step 2: Minimize water flows - The overall aim is to minimize the use of water in the
process in order to obviate effluent production or, if that is not possible, to produce more
concentrated effluents. It will be necessary to identify the minimum quantity of water that is
needed (or produced) by each step of the production process and then to ensure that these
requirements are implemented by such practices as:
● Use of water-free techniques for vacuum generation (e.g., use the product as a sealing
liquid in vacuum pumps, use dry pumps)
● Employ closed-loop cooling water cycles.
● Use management tools such as water-use targets and more transparent costing of
water.
Install water meters within the process to identify areas of high use.
Step 3: Minimize contamination - Wastewaters are created by contamination of process

water with raw material, product, or wastes; either as part of process operation or
unintentionally. The following techniques can prevent this contamination:
Process operation:
● To condense or chill steam phases, use indirect cooling systems rather than direct
injection systems.
● Purer raw materials and supplementary reagents should be used (i.e., without
contaminants).
● Use non-toxic or low-toxicity cooling water additions (e.g., chromium-based
compounds).
From spills:
● Secondary containment should be installed on vessels and pipework that have a high
risk of leaking.
● Prepare spill contingency plans and place spill clean-up material (adsorbents, drain
plugs, etc.) at strategic locations throughout the installation.
● Separate collecting systems should be used to process effluent, sewage, and rainfall
(although combining effluent streams may provide treatment benefits in some
circumstances).

Maximize wastewater reuse - Even when wastewater is created or generated, it is not

always necessary to send it to a treatment plant.
2. Process Modification
In plants process:
Segregation of process waste streams is required for all in-plant treatment solutions. If a
given pollutant or pollutants have several sources, they must be separated from the main
wastewater sewer. Similar sources, on the other hand, can be pooled for treatment in a single
system.
In-plant practices are the sole determinant of the amount of wastewater to be treated. There
are two types of in-plant practices that reduce flow to the treatment plant. First, there are
reuse practices involving the use of water from one process in another process.
Second, there are recycling systems that reuse water for many purposes. Water conservation
may be more cost-effective than water reuse or recycling in minimizing the amount of
wastewater released. One low-cost way of wastewater reduction is good housekeeping. Many
of the wastewater streams may be recycled within the facility.
Methanol - There should be no ignition sources such as open flames, sparks or smoking in
the vicinity of methanol storage or use. Contact of methanol with oxidants should be avoided.
Methanol must be used and stored in cool closed systems with adequate ventilation and
explosion-proof electrical equipment and lighting.
Methanol is a commonly used solvent in many organic reactions, and the resulting spent
methanol is considered a hazardous waste in the United States. Distillation of the spent
solvent to recover methanol for recycling is a standard process.
However, some contaminants may be too difficult, hazardous, or expensive to remove. In

such cases, spent methanol waste may find use as secondary fuel for energy recovery.
In the future, new processes with new catalysts will be used for recovery of waste organic
materials. As with the de-nitrification application in sewage water treatment plants, described
in a subsequent section, methanol will be used to reduce waste from existing processes and
reuse waste from other waste streams

Effects on organisms in the environment - Methanol is readily degraded in the environment

by photooxidation and by biodegradation processes. Many genera and strains of
microorganisms are capable of using methanol as a growth substrate. Methanol is readily
degradable under both aerobic and anaerobic conditions in a broad spectrum of
environmental media including fresh and salt water, sediments and soils, ground water,
aquifer material and industrial wastewater.
Detrimental results of methanol -
Methanol is released to the environment during industrial uses and naturally from volcanic
gases, vegetation, and microbes. Exposure may occur from ambient air and during the use of
solvents. Acute(short-term) or chronic (long-term) exposure of humans to methanol by
inhalation or ingestion may result in blurred vision, headache, dizziness, and nausea. No
information is available on the reproductive, developmental, or carcinogenic effects of
methanol in humans. Birth defects have been observed in the offspring of rats and mice
exposed to methanol by inhalation.
EPA has not classified methanol with respect to carcinogenicity.
Liquid Effluent Discharge Guidelines -
● Liquid effluent discharges into recipient water bodies must comply with standards
governed by laws and regulations adopted in each country.
● No liquid effluent should be dumped into rivers or other areas where infiltration may
occur without proper treatment.
● Materials that may seep due to rain should be stored in covered storage facilities with
drainage systems to prevent rainwater contamination.
● Liquid effluents may be treated by neutralization, evaporation, aeration, flocculation,
oil and grease separation, carbon adsorption, reverse osmosis, ion exchange, bio-
treating, etc. depending on the contaminate to be removed.
● The performance of applicable and demonstrated wastewater treatment technologies,
process changes, and pollution prevention strategies to reduce pollutants in an
industrial category’s wastewater

4.1.3 Solids Disposal

INTRODUCTION
RCRA states that "solid waste" means any garbage or refuse, sludge from a wastewater
treatment plant, water supply treatment plant, or air pollution control facility and other
discarded material, resulting from industrial, commercial, mining, and agricultural operations,
and from community activities. Nearly everything we do leaves behind some kind of waste.It
is important to note that the definition of solid waste is not limited to wastes that are
physically solid. Many solid wastes are liquid, semi-solid, or contained gaseous material.
Based upon modes of generation, chemical solid waste streams fall into two main groups, i.e.,
Intermittently Generated Wastes and Continuously Generated Wastes
Intermittent wastes are generally those that result from cleaning within the process areas and
off-site facilities. The following are typical intermittent waste streams:
• Spent catalysts from certain processing units and product treatment wastes such as
spent filter clay
• Process vessel sludge, storage tank sediments, vessel scale, and other deposits
generally removed during turnarounds
• Annual volume of intermittent wastes is strongly a function of individual plant waste
management and housekeeping practices.
Continuous wastes (those requiring disposal at less than two weeks interval) can be further
can be categorized into two groups viz. process unit wastes and wastewater treatment wastes.
Construction Phase-
During construction, solid waste will comprise domestic waste and construction waste from
the plant area. Domestic waste quantities are expected to total approximately 1.5 ton/day
during the peak construction (1500 personnel on site). Construction waste will depend on a
range of variables that cannot be defined exactly at this stage of the environmental impact
study. However, it is expected to include:
• Soil (excavated or surplus);

• Packaging materials (imported and local plastic, cardboard, paper and pallets);
• Damaged products (plasterboard, bricks, tiles, etc.);
• Packing timber;
• Geotextiles;
• Paving materials;
• Electrical cable off-cuts;
• Concrete;
• Miscellaneous containers, paint cans, solvent containers, aerosol cans, adhesive, and
lubricant containers
Operational Phase-
A large industrial site such as the proposed Methanol plant, will typically generate a large
quantity of domestic or “household” waste. This includes plastics, clean cardboard boxes
from deliveries to stores, and food scraps in addition to process related solid wastes and other
solid wastes. The type and anticipated annual quantities of solid wastes during the operation
phase of the project are detailed in Table 1.
Table 4.1: Estimated Solid waste during Operation
WASTE STORAGE AND RECYCLE

1. Storage
Wastes awaiting disposal must be stored in an environmentally acceptable manner, and shall
not lead to secondary environmental problems such as odor or pollution of groundwater due
to rainwater percolation through or run-off from the site. Storage should best be in closed
vessels, containers or bags, on a site surrounded by a bund wall or toe wall, with drainage to a
prepared system. Special precautions are of course required for pyrophoric materials to
eliminate the risk of fires; they must be kept wet, sealed or blanketed with inert gas.
2. Recycle and Reuse

The methods applied vary with the type of waste. The aim of recycle and reuse methods is to
reuse the waste for its original purpose or to find an alternative use for it to avoid its final
disposal. Therefore, waste production is reduced while natural resources are conserved and/or
protected.
Most of the reuse practices reported in the environmental statements are for off-site recovery
from waste streams. The material is to be sold to only authorized agencies with necessary
approvals.
All disposals must be carried out at authorized and assessed landfill facilities
SOLID WASTE POLLUTION ABATEMENT TECHNOLOGIES BASED UPON

TYPES OF POLLUTANTS
• Catalysts: Catalysts have a finite life because of chemical deactivation, physical
degradation or fouling. Catalysts are often based on expensive, exotic metals and this
provides an economic incentive for catalyst regeneration (either on or off site). Inert
catalyst supports are landfilled when they are physically no longer useful.
• Spent purification media: Media such as activated carbon, molecular sieves, filter
media, desiccants, and ion exchange resins are used to purify the product of
impurities. Wherever possible the media may be regenerated, but landfill disposal and
incineration (under appropriate conditions) may also be used.
Methods of Solid Waste Disposal and Management

1. Salvaging
2. Sanitary Landfills

3. Incineration
4. Composting
5. Ploughing in fields
6. Hog feeding
7. Grinding and discharging into sewers
8. Fermentation and biological digestion
4.1.4 Noise Pollution

Noise is a major hazard that can occur in all many processing operations. Sound can be
considered a natural nuisance and can be reduced repeatedly to use simple techniques (mute
or screen for example). However, the sound levels will not translate into high levels of
exposure due to staff movement within operations and functions, as well as equipment that
does not work continuously.
In this era of noise pollution pollution is high due to the growth of the country's industries.
Chemical plants have a role to play in due to high-speed gases and heavy equipment
components such as pumps, compressors, heavy machinery and blowers etc. Excessive crop
noise can lead to complaints from neighboring factories and residents.
In the immediate vicinity of the petrochemical industry, high noise levels create noise
pollution associated with headaches, irritability, discomfort, depression, impatience,
unhappiness, extreme sensitivity, extreme anxiety, anger, vulnerability and violence.
The reduction in noise in the methanol plant should be considered as follows:
• When buying or designing machinery and equipment, sound levels will be considered.
Additional costs for selecting equipment with a relatively low noise level is low in this
category. Reduce noise emissions after which it is very expensive.
• Use tools to reduce noise creation.
• Plant structure should be established to consider the feasibility of reducing noise production
and noise levels within the site boundary, especially in the vicinity of sensitive areas.
The methanol industry has a large number of major noise pollution sources including: -

1. Compressors (Natural Gas, Syngas, ASU High Pressure MAC, and ASU Air booster
“BAC”);
2. Turbines (natural gas, Flue gas, Combustion air, Syngas, HP BFW pump, and ASU
Compressor steam);
3. Air Coolers; - Fans (Flue gas, and hot air);
4. Pumps (ASU steam turbine condensate, MAC condensate, water chiller, HP LOX, LP
LIN, LP saturator circulation, HT saturator circulation, process condensate, Topping
column reflux, Topping columns bottoms, Refining Column Reflux, recovery column
reflux, Fusel oil, Lower column recovery, Process sump, HP BFW, Startup BFW, and
fluid transfer
5. Flares
Noise Level Standards The CPCB has specified specific area levels for noise level (day
and night time) shown below.
Table 4.2: Noise Level Standards
Standard of Noise Levels
Area dB(A) Limits
Day Night
Industrial 75 70
Commercial 65 55
Residential 55 45
The National Institute for Occupational Safety and Health (NIOSH) has recommended
that all worker exposures to noise should be controlled below a level equivalent to 85
dBA for eight hours to minimize occupational noise induced hearing loss.
Noise Pollution Reduction Measures-

It is important to provide protection from exposure to sound when the noise level exceeds the
indicated limits. The noise reduction program should begin with the determination of the
actual source and route of travel. It is important to minimize noise sources such as steam
locomotives, gears, power systems, exhausts and anything else. The most common way to
control and reduce noise is given below:
1. Vibration Isolation: If part of the structure is the main cause of noise or vibration
transmission, the separation may be restored to a possible reduction from 5-30 dB.
2. Surface Damping: For lightweight transmitters or glittering straps tied to damping
tapes or lethal objects may be used.
3. Incomplete Obstacles: Absorbent telephone booth, acoustic absorption of a large
internal area, and a wall that distorts unwanted external noise can significantly reduce
overall levels.
4. Line Pipelines: When transmitting equipment, the line pipelines can reduce noise
escape. Usually, a sound-absorbing membrane is used.
5. Mufflers: When handling large amounts of fluid or in a group of closed car driving
units, pumps, ejectors etc. Mufflers can help reduce noise to acceptable levels.
6. Control valves: High pressure gas, steam and liquids can be a source of serious noise
pollution. Separating the pressure between two valves instead of one can reduce noise
pollution.
7. Enclosures: Sound source must contain its wall gasket doors.
8. Acoustic Absorption: Place acoustic material on ceilings and side walls. Ear plugs or
muffles can be used by the plant to block out noise.
4.2 Energy Conservation
Global oil resources are dwindling rapidly and there is an urgent need to test the feasibility of
other energy sources. Although rapid success has been achieved in the use of nuclear energy
in the digestion of steam, which it is used to generate electricity, it is not used much due to
shortage of flexibility in its use and due to its inefficiency on a small scale.
Using Other Sources of Energy:
Solar power:

Solar energy is the most important form of renewable energy in a plant. In a power event on a
solar panel installed on the roof and other vegetation areas they are very useful for heating
water and are converted into steam. This is one renewable energy source that is now gaining
widespread acceptance in the gradual process industry. In the process industry heat is widely
used process water and, in some cases, produce steam pressure, Energy conservation is not
just about the process industries but also relating to other small household purposes made in
industrial areas extensively for the heated process of water and in some cases that production
can also be used for heating and providing hot water in the canteen as well other production
areas in the process industry.
Marine Energy:
Marine energy is one of the contributors to renewable energy. Temperature seawater varies
greatly in depth. The goal here is to run heat engine to dissipate sea heat energy through
differential sea temperature at various depths. This technology is in its infancy growth stages
and can only be used when the plant is close by on the beach.
Wind power:
The unequal heat of the earth by the sun causes winds. This effect is particularly pronounced
in coastal areas with a difference in temperature between land and sea. Wind power is used to
alternate windmills, i.e., rotating blades to collect wind power. This mechanical force
produced can be used directly and it can be converted into electrical energy. These have been
used successfully in part in the process industry, especially for pumping water for both fixed
water and water in waste disposal facilities. 3.5 m wide grows about 0 to 60 hp in 15-mph air
and can pump 35 litres of water per minute to a height of about 10 m.
Energy from Waste Streams
The waste streams in the plant should be analysed. If they contain sufficient energy to heat up
process streams, instead of dumping those streams, they can be used to generate heat or heat
up the process streams.
Process Change in Methanol Production for Energy Conservation-
There are 2 ways in which in which energy efficiency can be achieved:

• Improvement In Operating Process
• Improvement In Maintaining Process

1. Another development that is a major turning point in the entire chemical industry is
also recent continuous implementation of improved and efficient control. Controlling
traditional process including monitoring and modifying parts of the chemical industry.
Additional ideas include changes in economic values, such as current prices and
supply / demand issues for immature goods, services, and products. The model
controls hundreds of results to adjust process conditions as well incorporates built-in
barriers to ensure the safety and effectiveness of targeted environments.
The chemical industry continues to find creative ways to recycle and recycle waste.
All one has to do is remove the dirt from the dirty water. If contaminates are present
removed, this can also be used, for example to produce high pressure fumes. After
steam used in production processes, water is also used in cooling towers until they
evaporate at the end in space.
2. An integrated approach using simulation models and a new integration strategy, called
Effect Modelling and Optimization (EMO), has been used to improve process
efficiency. The method allows us to identify different ways to improve the efficiency
of the process. The adjustment affects the reaction reactor and the changing reactor
designs, the exploitation of the cleaning stream such as gasoline to meet the process
requirement and its integration into the gas turbine system. The EMO approach allows
to identify the impact of process change at the global level of process energy costs,
including the combined production of heat and power equipment in a gas turbine and
steam network.
3. The CO2-to-methanol combined with solid-oxide electrolysis (SOE) process can store
renewable energy in methanol while re-digesting CO2, thus achieving the twin
objectives of storing more renewable energy and reducing lifelong CO2 emissions.
This paper focuses on the techno-economic development of CO2 hydrogenation to
synthesize raw methanol combined with the process of solid-oxide electrolysis.
Process integration, techno-economic testing, and multidisciplinary performance were
performed in the case study. The results show that there is a trade-off between energy
efficiency and the cost of producing methanol. The annual methanol yield for the
taught case is 100 kton with a purity of 99.7% wt and annual CO2 consumption of
150 kton, representing the final annual capacity of 800 GWh of renewable energy.
Although the efficiency of the system is about 70% and varies over a short distance,

the cost of producing methanol reaches 560 $ / ton with an electricity price of 73.16 $
/ MWh, which is not economically feasible during the 13-year recovery. If the price of
electricity is reduced to 47 $ / MWh and proceeds to 24 $ / MWh, the cost of
producing methanol is 365 and 172 $ / ton over an attractive payment period of 4.6
and 2.8 years, respectively. The price of electricity has a huge impact on the
implementation of the project. The price of electricity varies from country to country,
resulting in a difference in payment times in different places
4. The concept of CO2-to-methanol integrated with SOE is designed and developed
from a techno-economic perspective. Significant problems studied with the CO2-to-
methanol process associated with SOE include: (1) systemic temperature fluctuations;
(2) the effects of operational variables on system performance, e.g., system efficiency
and cost. To achieve this, the CO2-to-methanol process combined with SOE has been
modelled and investigated by a multi-objective optimization (MOO) field considering
the calculation of thermal flow.
5. Plant Utilities
ABSTRACT
Any Chemical Plant requires raw materials in order to produce final products. It also requires
various other services called Utilities for smoothly carrying out the processes. Utility is
neither a reactant nor a product, But Utilities are required for maintaining adequate conditions
of a manufacturing unit. Utility area is an important area of a Chemical Plant. This may house
various Boilers, Large Compressors, Refrigeration systems, Air Conditioning systems, Water
Treatment Plants, Cooling Towers etc.
Utilities situated outside plant limits should not give any wrong impression that utilities are
any less important than the main process, because it is the Efficient Management of Utilities
that generate Profits. The utilities help to maintain proper process conditions like pressure,
temperature etc., without which it will be impossible to carry out the process. For example, if
Steam at higher temperature than desired enters Heat Exchangers, the Exchangers may get
damaged. Air, water, steam, refrigeration, fuel, furnace, insulation etc. are the common
utilities used in Chemical Plants.

5.1 Air System

Air systems are necessary for daily plant operations. Plant and instrument air are both
supplied from centrally located air compressors. Drivers for the compressors are arranged so
that the loss of power or steam will not interrupt the supply of critical instrument air. Some
plants have additional diesel-driven compressors in case the two utilities (electricity and
steam) are not available at the same time.
There are usually two separate systems and these are:
1. PROCESS AIR SYSTEM
2. INSTRUMENT AIR SYSTEM
Plant Air System
The function of utility air systems:
● Provide air to operate various plant equipment and tools

● Provide air for process use
● Decoking furnaces and regenerating catalysts
● Dry equipment
● A central utilities unit supplies utility air for the entire plant. Free water is removed at
a separator drum that is located off the air compressor discharge but is not dried. The
largest use of utility air is in the decoking unit furnace, which is operated
intermittently. Usually, an extra air compressor is put online during these periods.
Utility air should never be used for unplugging lines or sewers or for removing liquid
hydrocarbons from trucks or vessels because of the hazard of creating combustible
mixtures.
Instrument Air System
The purpose of instrument air systems:
● Provide air to operate valves

● Provide clean, dry purge air
● Instrument air is dried to approximately – 45.55°C dew point with activated alumina
desiccant. Instrument air system pressure is protected against low pressure (as a result
of excessive utility air usage) by an upstream pressure controller in the utility air
system. This control valve will close off if the instrument air header pressure falls
below 95 psig. It is important to maintain the instrument air system pressure at its

normal controlled pressure of 105 psig, because some control valve actuators begin to
malfunction when the pressure drops below 60 psig.
● At some locations the plant instrument air system is protected against pressure failure
by a tie-in to the nitrogen (N2) system. Because of safety concerns, nitrogen is
admitted into the instrument air system only during an emergency. An alarm or alert
system is in place to warn all unit personnel whenever nitrogen is added to the
instrument air header.
5.2 Heat Transfer Media

Heating utilities are required for the correct operation of distillers, reactors, condensers, and
other critical equipment. Steam, fired heat, fuels and hot oil/specialized heat transfer fluids, in
particular.
Type and Requirement:
STEAM:
Steam is usually raised in a boiler. It's a good idea to have at least two boilers, each capable
of generating around 75% of the total load, so that the plant can keep running—albeit at a
reduced capacity—if one goes down for maintenance or fails. Food-processing boilers
typically create steam at 100–150 psi, which is lowered as needed at the point of application.
In the food processing industry, considerably higher-pressure steam is rarely required.
Steam is often supplied using threaded carbon steel pipe. Steam traps should be installed at
low spots in the pipes to remove condensate. Steam traps should be discharged directly to
drains or condensate-return systems. To preserve heat and highly treated water, condensate is
collected. Scale formation, which increases processing costs by limiting heat transfer rates
and blocking pipes, can be reduced by softening boiler feedwater. If rust and corrosion
products are picked up by steam and condensate in carbon steel pipes, they will quickly
discolour the floor if released there.
Culinary steam is created specifically for interaction with food. Chemicals are frequently
injected into boiler feedwater to prevent corrosion and scale development in the boiler and
pipework, although these chemicals are rarely intended for human consumption. Culinary
steam is produced by heating purified water with high-pressure steam in a heat exchanger.

The cooking steam is purified and routed to its final destination in stainless steel. Culinary
steam is usually generated close to where it is utilized to save money on stainless steel pipes.
Natural gas is commonly used to power boilers, although they can also be powered by coal,
fuel oil, or waste. Various than natural gas, other fuels may necessitate the use of specialized
boilers. Special controls are required in boilers that employ wastes such as paper, wood, or
agricultural residues to compensate for the varied heating values of these fuels. With the
rising expense of fossil fuels and a growing focus on sustainability, it's possible that food
factories may increasingly employ alternative fuels in steam boilers.
Other heat sources for processing include closed-loop hot-water and hot-oil systems. These
employ steam or fuel to heat a circulating medium, such as water, under pressure (so it can
reach temperatures beyond 212°F) and heat-stable oils that can reach temperatures above
500°F. Circulating fluids may be preferable to steam since they do not carry the same risks as
steam and, in the case of oil, can reach higher temperatures than steam can. They can also
maintain a consistent temperature in industrial equipment. While boilers are often situated
near the use point to reduce distribution costs, circulating systems are considered part of the
process and are typically located close to the use point.
A licensed operator is normally required to operate a high-pressure, stationary boiler. This

might be a specifically trained member of the maintenance team with added responsibilities.
Steam below 15 psi does not require a license and is frequently sufficient for food processing.
Boilers should be placed against an outside wall, with access to fresh air for combustion and
enough space to draw tubes if necessary. A big, louvered panel is frequently utilized for air
intake as well as possible access. For the boiler stack, an air-emissions permit is normally
necessary. The combustion products of most natural gas do not need to be treated before
being discharged, although coal or waste fuels may, depending on their sulphur level and the
boiler's efficiency.
Fired Heat:
In many cases, processes in a plant require a heat source stronger than high pressure and
temperature steam. That is when fired heat is used, which is generally at temperatures above
523K. Streams can be heated directly in the furnace tubes or via a hot oil circuit or heat
transfer fluid, which will be discussed in detail in the next section. Most fired heaters use

natural gas as fuel because it burns cleaner than fuel oil. A cleaner burning fuel is always
advantageous due to environmental and safety concerns. Furthermore, natural gasses usually
result in less wear and tear in burners and fuel lines.
Fuels:
Fuel is burned in utility facilities such as boilers, electricity generation, and cogeneration, and
can be in solid, liquid, or gas form. It can also be burned to provide heating for a process or
stream or to drive pumps and compressors. The fuel is usually burned with excess air to
ensure complete combustion.
The heating values can be used to quantify the quantity of heat generated. The terms "higher
heating value" (HHV) and "lower heating value" (LHV) are used interchangeably. The total
heat produced by full combustion of a fuel with dry air at 60 degrees Fahrenheit, with both at
60 degrees Fahrenheit and the flue gas after combustion cooled to 0 degrees Fahrenheit, is
referred to as heating. The LHV is obtained if the water vapor in the flue gas is not
condensed. When water vapor is condensed, the heat evolved has a slightly greater value,
which is the HHV. Solids and liquids are normally measured in terms of mass, whereas
gasses are measured in terms of volume.
The amount of fuel computed using simply the HHV is insufficient to meet a required
amount of heating. There will be heat losses, the flue gas temperature will be over 60 degrees
Fahrenheit, and the water in the flue gas will most likely be vapor.
Hot Oil/Specialized Heat Transfer Fluids:
When steam and fired heat are insufficient, specialized heat transfer fluids and hot oil circuits
are employed as heat sources. Specialized heat transfer fluids and hot oil circuits are
incredibly adaptable, allowing them to operate at temperatures ranging from 323 to 673
degrees Fahrenheit. This range, on the other hand, is highly changeable. The upper
temperature limit for hot oils is determined by the oil's thermal breakdown and the
coking/fouling of heat exchanger tubes.

5.3 Water
Water is important in food processing as an ingredient, for cooling, and for cleaning. Water
must be potable, which means it is fit for human consumption, but even potable water may
require extra treatment to eliminate chlorine and suspended particles. Ion exchange is
commonly used to reduce hardness from boiler feedwater, as previously noted (calcium and
magnesium salts that can form scale). Water used for cooling can be reused for cooling or for
other reasons, such as cleaning, by returning it to a cooling tower. Chemicals may be added
to water in a closed cooling circuit to decrease scale and corrosion; in this instance, care must
be taken to ensure that the water does not contaminate food.
Water can come from a well or a surface water source like a lake or river, or it might come
through a public or private utility. If a company provides its own water, it is responsible for
testing and treating it to ensure that it is safe to drink and process. Water quality fluctuates
with the seasons and weather, while subterranean water has less variations than water from
other sources.
The majority of water entering a facility is eventually dumped into a sewer and subsequently
into the environment. Water, which is utilized in the product, is an exception. If the
difference is significant, it's a good idea to separate the incoming and outflow water meters
and negotiate prices based on actual usage. Otherwise, sewage costs are frequently based on
incoming water rates, with the assumption that incoming and disposal rates are about equal.
Water can be delivered by carbon steel, plastic, or copper tube. Ingredient water should be
delivered in a stainless-steel tube in process locations.
Process and General Water Requirement and Standard
A plant water supply is separated into process, boiler feed, cooling, potable, fire water and
utility
water systems. Brief descriptions of the different water use in refineries are given below.
Process water: Water is commonly employed for a variety of reasons in which it comes into
direct contact with hydrocarbons. For these uses, softened water is frequently utilized.

Boiler feedwater: Boiler-feed water (BFW) is used to produce steam. These systems are
designed to remove solids, turbidity, and dissolved gasses from water fed to the boilers. This
helps protect the boilers from fouling, etc. Feedwater is sent through a series of equipment
designed to remove solids, turbidity, and dissolved gasses from water fed to the boilers.
This helps protect the boilers from fouling, corrosion, and other operational problems. The
water and
A steam condensate stream is heated in the boiler where additional solids are removed and
turned to steam. A recycle/reflux stream returns through the system for additional recovery.
Steam produced in the system is used in the plant for a variety of purposes.
Cooling Water System: Cooling water systems (with or without cooling towers) are
essential to facility operations. They remove heat from process streams and equipment by
circulating water. The cooling water (CW) system is used for cooling the various pieces of
equipment in the facility in a closed cooling system. The cooling water system is divided into
three complementary circuits. Cooling water is used to cool the process up to atmospheric
temperature. Cooling towers are used to produce cooling water. There are different types of
cooling towers available, like natural draft cooling towers, mechanical drafts cooling towers
.The main advantage of cooling towers is that they are very cheap compared to chilling . The
main disadvantage of cooling tower water is, it cannot be used for cooling Bello 25 degree
Celsius.
Potable water: In refineries, potable water must be used in kitchens, wash areas, and
restrooms, as well as in safety showers and eyewash stations. This may be done with either
city water or treated groundwater. A part of the treated water from the plant softening unit
may be redirected for potable water consumption in rural places or small communities. To
avoid cross contamination, the treated water must be chlorinated to kill bacteria before being
injected into a separate system. Some specialty chemical activities may also necessitate the
use of potable water (e.g., as a diluent).
Fire water: The need for fire water in refineries is infrequent, but it can amount to a huge
flow. Refineries frequently collect rainwater from non-process areas and store it in a reservoir
devoted to the plant's fire-fighting system. Typically, provisions are provided for the fire
water system to be connected to the largest accessible reservoir of water (for usage in

emergency scenarios). Because fire water does not require treatment, this is usually the raw
water source. Plants in coastal locations frequently utilize sea water or brackish water as fire
water.
Utility water: Utility water is utilized for a variety of cleaning tasks, including cleaning an
operational space. It should be clear of silt, but no further treatment is required.
Cooling Tower: A heat rejection device is an industrial cooling tower. It removes waste heat
from the water, lowering the water's temperature. It is used in industry to lower water
temperatures and so provide cooling water for processes.
Types of cooling tower:
There are different types of industrial cooling towers
Cross flow Cooling Tower: In a crossflow cooling tower, hot water is sprayed from the top
which is perpendicular to air which enters from the sidewalls of the tower horizontally and
then rises upward from the center of the cooling tower. In crossflow cooling towers air enters
at 90 degrees in the direction of the water. As the flow of water and air cross each other, these
types of cooling towers are called crossflow cooling towers.
Counter flow Cooling Tower: In counterflow cooling towers, the water is sprayed through
the pressure nozzles near the top of the tower and flows down through the fill material and air
entered beneath fills and moves upward opposite to the direction of the water flow. As the air
flow and water flows in the cooling tower are in counter to each other, these cooling towers
are called counter flow cooling towers.
5.4 Refrigeration System

The purpose of a refrigeration system is to remove heat from a process requiring less than
ambient temperatures. Some of the applications of refrigeration systems in industry are:
● To chill process flow

● To condense gas so it can be handled as a liquid
● To dry air or other gasses

In the refrigeration process, low-pressure refrigerant gas is drawn into a compressor,

converted into high-pressure refrigeration gas, and pushed into a shell and tube heat
exchanger. During the compression process, a tremendous amount of heat is generated and
must be removed by the exchanger. During the cooling process, the gas condenses into liquid
phase and is collected in a receiver. From the receiver, the high-pressure liquid refrigerant is
pushed through a small opening in an expansion valve. As the liquid expands, it changes
phase. The boiling point of the refrigerant is so low that a cooling effect occurs in the
evaporator. As the low- pressure refrigerant leaves the evaporator, it enters into the suction
side of the compressor and the process begins again.
5.5 Electricity
Electricity is usually supplied to the site by a high-voltage line from the local utility. The
plant must first build a step-down transformer, followed by an electrical distribution system
with several voltage levels, including 440 V, 220 V, and 120 V. The higher the voltage, the
less expensive the wiring will be and the more effective the conversion of electricity to
productive work in equipment motors or light from fixtures will be. Individual pieces of
equipment and plant regions are frequently connected individually so that they may be
separated. Switchgear and motor starters create heat; thus, they should be kept in well-
ventilated areas. Because much of the switchgear is rarely used, it might be found in isolated
locations.
Control and communications wire is often low voltage; therefore, it should be kept separate
from power cable. Wire in a food plant is usually encased in metal conduits, which protect it
from water, dust, insects, and rodents as well as unintentional damage. Over-filling conduits
is not a good idea. Good practice is frequently dictated by local codes. For ease of cleaning,
conduits should not be put too close together. For the same reason, conduits should be one
inch away from walls, and hangers should be of the same hygienic design as utility and
process piping—that is, no perforated channel and no all-thread rods, which are difficult to
clean and can cause damage with their sharp threads.
The prominence of computers in contemporary industrial processes necessitates the use of a

stable power supply. One solution is to have electricity provided from two separate
substations, so that at least one is always available, however this is not always practicable.
Another option is to use a natural gas or diesel-fuelled standby electrical generator. A large,
battery-operated uninterruptible power supply (UPS) that can detect a dip in incoming

voltage, supply power momentarily, then switch to another source is frequently used to
augment the generator.
Few food plants are self-sufficient in power, but this might change in the future, especially if
the facility can also utilize waste heat from a generator. This is referred to as co-generation. A
gas turbine or a huge diesel engine can power the generator. Local utilities are required to
acquire extra electricity generated by private parties in some places. The utilities may not pay
a particularly high price unless otherwise compelled by law, because most utilities seek to
discourage co-generation because it entails a loss of business for them. When it comes to
negotiating advantageous energy tariffs for a new plant, the threat of investing in co-
generation is typically helpful.
Electricity is the main component in today’s era when the control is done with the help of
different automated instrumentation which automatically control the flow rate, temperatures
of different heating devices and pressure building devices. For all such controls the need of
electricity is a must in the industry. Total power consumptions will depend upon the amount
of heat generated with electricity and how much heat is produced from boilers. Required
electricity = 29005200 KWh.
6. Organizational Structure and Manpower Requirement
6.1 Organizational Structure
Any significant organisation's organisational structure centres primarily around two sorts of
employees:
1. Outsourced Staff
The contracting out of a company process to a third-party is known as outsourcing.

Outsourcing Employees and assets are sometimes transferred from one company to
another, but this is not always the case.
The practice of giving over control of public services to for-profit firms is also known as
outsourcing. A contractual arrangement including the exchange of services and payments
between two organisations is possible. Outsourcing is claimed to assist businesses to focus
on their core competencies while also addressing skill or knowledge gaps in the areas they
seek to outsource.
2. In-House Staff

Instead of depending on outsourcing, an in-house structure involves doing an activity or

operation within the organisation. It's possible that a company will strive to keep the entire
transaction in-house. A brokerage may attempt to match a customer's order with that of
another customer, resulting in an in-house transaction. As a result, the firm can profit from
both buy-side and sell-side commissions.
Introduction:
Individuals and groups of people engage in a systematic process in which they act and react
continually to achieve defined goals. It is both a structure and a process or a collection of
ongoing operations. The human side of an organisation is represented by the interaction and
interdependence of members in order to attain a goal.
The following are the organisational principles:

1. There should be a clear chain of command from the top down. Despite the fact that each
person should be accountable to only one person, he should have access to his higher
authorities.
2. Authority and responsibility must be linked.
3. An executive's authority must be limited to the number of subordinates whose activities
can be properly coordinated.
4. Over organisation must be avoided.
Our unit's organisational structure can be divided into three categories:
a) Top management organisation
b) Operating line management
The company's top management structure is of the staff type, with different levels of
management based on the individual's roles and responsibilities. It is made up of general
management or administrative personnel who supervise and oversee divisional or
departmental management workers. The board of directors is responsible for representing,
safeguarding, and advancing the stockholders' interests in top management, determining basic
policies and the general course of business, evaluating the adequacy of overall results, and
generally protecting and maximising the use of company assets.
DEPARTMENTS
General Administration

A general manager will be in charge of the organisation. He'll be in charge of a variety of

tasks, including:
a) Make quick and essential decisions to make the job easier to complete.
b) Ensure that the factory runs smoothly and profitably.
b) Develop and carry out a diversification strategy.
d) Maintain cross-departmental coordination.
He will be in charge of the company or organisation in a wide sense. A manager may be in
charge of one functional area, but the General Manager is in charge of all of them.
Subordinate managers report to General Managers. A General Manager, on the other hand,
may have people reporting to him who aren't managers. He has the authority to hire, fire, and
promote people.Higher-level planning will be the responsibility of the General Manager. A
General Manager is often in charge of the company's or organisation's overall strategic
planning and direction, leaving the day-to-day management of the many departments to the
managers.
Production Division
A production manager is in charge of this department. He must be a technical person who is

in charge of the plant's total production and flawless operation. Production is the department
in charge of converting raw materials into finished goods through a series of manufacturing
procedures. The production manager is in charge of ensuring that raw materials are delivered
on time and that final goods are produced efficiently. He or she is responsible for ensuring
that work runs smoothly and for supervising practises that make work more efficient and
pleasurable. The production function of a manufacturing company can be divided into five
sub-functions:
Purchasing Department
The purchasing department will be in charge of supplying the necessary materials,

components, and equipment to keep the manufacturing process going smoothly. One of the
most important aspects of this job is ensuring that the supplies arrive on time and in good
condition.

Stores Department
The stores department will be in charge of stocking all of the necessary tools, spares, raw
materials, and equipment to keep the manufacturing operations running smoothly. When
sourcing is unpredictable, buffer stocks must be preserved, and the usage of a computerised
stock control system helps keep stockpiles at a minimum yet essential level to ensure
uninterrupted production.
Production and Planning Department
Each component of the production process will have standards and targets defined by the
production and planning department. With firms focusing on lean production, the quantity
and quality of items coming off a production line will be closely checked. Quality will be
monitored by all employees at every stage of production, rather than at the end, as it is in
organisations utilising the quality control approach.
Design and Technical Support Department
The design and technical support department will be in charge of studying new products or
making changes to existing ones, as well as predicting production costs in various amounts
and using various methods. It will also be in charge of the development of prototypes and
testing of new product processes and product types, as well as the design and testing of new
product processes and product types. Work study and advice on how to enhance working
practises may also fall under the purview of the technical support department.
Works Department
The manufacturing of products will be the responsibility of the works department. This will
involve the upkeep of the production line as well as any other repairs that are required.
Quality control and inspection may also fall under the purview of the works department.
Marketing Division

Designing a set of defined goals, objectives, and strategies for the organisation's marketing
efforts is one of the most significant functions of the marketing division. This entails defining
guidelines and a business idea for how the company will conduct itself in the marketplace, as
well as what marketing instruments will be employed, what goals will be set, and what
techniques will be used to achieve successful advertising campaigns. This marketing
department creates a market-based business plan that gives customers with distinct value
across all of the company's services and products. A marketing engineer is in charge of this
department. He is in charge of developing new marketing strategies, as well as public
relations, advertising, sales, and product complaints.
Finance Division
There are various functions to be completed when it comes to the overall scope and tasks of a
finance department. The majority of the responsibilities revolve around budgeting.
The finance department of any given organisation is responsible for a wide range of tasks,
including appropriations, expenditure control, and auditing.
The five primary functions of a finance department are as follows:
1. Accounting processes
Keeping track of a company's purchases and sales, as well as capital expenditures.
2. Creating a profit and loss account and a balance sheet

Financial statements must be made at regular periods, such as at the conclusion of each
quarter. The fiscal year To construct a balance sheet, trial balances are extracted from ledger
entries displaying the company's assets and liabilities
3. Providing information to management

Managers demand continuous financial data in order to make better decisions. They will, for
example, want to know how much it costs to manufacture a specific product or service in
order to determine how much to produce and whether it is worthwhile to switch to a different
product.
4. Wage administration

The finance department's wages branch will be in charge of calculating employee wages and
salaries, as well as organising the collection of income tax and national insurance for the
Inland Revenue.
Human Resources
The recruiting, selection, training, and development of personnel are the primary
responsibilities of Human Resources. This will entail training employees to reach their full
potential while also advancing the organisation's goals. Human Resources frequently takes on
a welfare function, which entails looking after employees while they are on the job. They
may also develop policies that strike a balance between the needs of the company and the
needs of the workforce. They will also interpret employee welfare legislation and guarantee
that the organisation is in compliance with the law.
Organisational Chart:
Figure 6.1: Organisational Chart

6.2 Manpower Requirement
Below tables lists the manpower requirement along with their roles, qualifications as well as
their salaries.
Table 6.1: Workforce Requirement
Designation Requirement Salary per month Qualification

Engineer + MBA with
President 1 ₹ 3,50,000.00 15 years of on-site
experience
Production Department
Engineer + MBA with
Vice President 1 ₹ 2,50,000.00 10 years of work
experience
Chemical Engineer
Production Manager 1 ₹ 2,00,000.00 with 10 years of work
experience
Production and
Industrial
Manager Operations
1 ₹ 1,60,000.00 Engineer/Mechanical
and Maintenance
Engineer with 10 years
of experience
Production and
Manager raw material Industrial/Chemical
1 ₹ 1,50,000.00
and stores Engineer with 8 years
of work experience
Production and
Manager quality & Industrial Engineer
1 ₹ 1,50,000.00
Testing with 8-10 years of work
experience
Chemical Engineer
Production Engineer 4 ₹ 75,000.00 with 4 years of work
experience
Mechanical Engineer
Maintenance Engineer 4 ₹ 75,000.00 with 4 years’ work
experience
Instrumentation
Instrumentation
3 ₹ 75,000.00 Engineer with 4 years
Engineer
of work experience

Chemical Engineer
Shift Engineer 10 ₹ 60,000.00 with 4 years of work
experience
Diploma in Chemical
Shift Operators 20 ₹ 50,000.00
Engineering
8 years of experience in
Deputy Manager fire
3 ₹ 75,000.00 fire and safety
& Safety
Management
Graduate with 4 years
Deputy Manager
1 ₹ 60,000.00 of experience in public
Environment safety
relations
MBBS with 4 years of
Medical Officer 2 ₹ 85,000.00
experience
Medical Staff 4 ₹ 40,000.00 Diploma
Marketing Department
MBA (Marketing) with
Vice President 1 ₹ 2,50,000.00
10 years of experience

Manager Sales 1 ₹ 1,75,000.00

Manager Marketing 1 ₹ 1,75,000.00

Manger Purchase 1 ₹ 1,75,000.00
8 years’ experience

Marketing Office 5 ₹ 75,000.00
some or no experience
Finance Department
CA with 10 years of
experience
MBA (Finance) with 8
Manager Finance 1 ₹ 1,75,000.00
years of experience
CA with 8 years of
Manager Accounts 1 ₹ 1,75,000.00
experience
B.Com with some or
Clerical Staff 1 ₹ 50,000.00
no experience
Human Resources Department
MBA with 10 years of
experience
Manager MBA with 10 years of
1 ₹ 1,75,000.00
Administration experience

Engineer + MBA with

Manager Training 1 ₹ 1,75,000.00
Deputy Manager Retired army or Police
2 ₹ 85,000.00
security official
Graduate of 5 years of
Deputy Manager
2 ₹ 75,000.00 Experience in public
Public Relations
relations
Table 6.2 Workforce Requirement
Staff and Labour

On contract and basic
Labour 100 ₹ 25,000.00
school qualifications
Master's degree in
Librarian 1 ₹ 80,000.00
library science
Bachelor’s degree in
Library Staff 2 ₹ 55,000.00
library science
Total skilled employees: 80
Total unskilled employees: 100
Total organization cost per month: ₹ 95 lakhs (approximately).
Total organization cost per annum: ₹ 11.4 crores (approximately)
7 Market prospects
7.1 Brief Analysis of Demand and Supply Of methanol
The global methanol market is projected to grow from $28.74 billion in 2021 to $39.18
billion in 2028 at a CAGR of 4.5% during forecast period, 2021-2028. This growth is fuelled
by the use of methanol as fuel in the automotive industry, increasing olefins production from
methanol-to-olefin (MTO)/ methanol-to-propylene (MTP) plants in China, and increasing
petrochemicals demand, globally.
Methanol is a polar solvent produced by fossil fuels such as Natural gas and coal. Methanol is
widely utilized as a process chemical in manufacturing highly valued derivatives such as
Formaldehyde and Acetic Acid. Since Methanol is considered an ideal alternative to reduce

carbon footprints, governments across various economies are coming up with innovations for
increasing the utilization of Methanol as an environment-friendly fuel.
Figure 7.1: Methanol Global Demand and Supply Balance

Top Key Players in Methanol Market Industry are:
• SABIC
• Celanese Corporation
• Eastman Chemical Company
• BASF SE
• Atlantic Methanol
• Methanex Corporation
Top key players operating in the Indian methanol Market:

GNFC, Deepak Fertilizers and Petrochemical Corporation, Rashtriya Chemicals and

Fertilizers and Assam Petrochemicals Limited are the key producers of Methanol; Iran, Saudi
Arabia and Brunei are the primary importing sources of Methanol.
In January 2019, SABIC announced that they had agreed with South Louisiana Methanol to
establish and develop a chemicals plant situated in the United States. This decision comes
after a significant rise in the demand for shale gas production from the region.
Figure 7.2: Global Methanol Pricing

Figure 7.3: Global Methanol market by Region
7.2 Present Production Capacity and Export Potential
India's current Methanol production capacity is less than one-third of the country's total
demand. The market is mainly dependent on imports coming in from the Middle Eastern
countries, which account for more than 75% of the Methanol coming into India. The Indian
Methanol market witnessed strong growth during the past five years, and it is further
forecasted to grow at around CAGR of 7.19% by 2030.
Production and Installed Capacity of methanol 2017-18 to 2019-20
Table 7.1: Production and Installed Capacity of methanol
Production Installed Capacity

Year
Million tonnes
2017-2018 0.260 0.474
2018-2019 0.271 0.474
2019-2020 0.176 0.474

During 2019-20, the top five Chemical products (in terms of value) imported from different
countries were Methanol (Rs.4,256/-Cr.), Acetic Acid (Rs.2,737/-Cr.), Other Insecticides
(Rs.2,680/- Cr.), Carbon Black (Rs.1,534/- Cr.) and Soda Ash (Rs.1,525/- Cr.). Methanol is
mainly imported from Oman, Saudi Arabia, Iran, Qatar & United Arab Emirates. Acetic Acid
is imported from China P RP, Malaysia, Singapore, Taiwan & Saudi Arabia, whereas
methanol export is only 2352cr.
Imports of Methanol 2016-17 to 2019-20 QTY in Tonne & VAL in Rs. Lakh
Table 7.2: Imports of Methanol
2016-17 2017-18 2018-19 2019-20
QTY VAL QTY VAL QTY VAL QTY VAL
1637457 295762 1783293 400004 1986712 519474 2286274 425567
Exports of Methanol 2016-17 to 2019-20 QTY in Tonne & VAL in Rs. Lakh
Table 7.3: Exports of Methanol
2016-17 2017-18 2018-19 2019-20
12624 3123 9466 2846 10943 3819 12941 3482
Net import of Methanol 2016-17 to 2019-20 QTY in Tonne & VAL in Rs. Lakh
Table 7.4: Net import of Methanol
2016-17 2017-18 2018-19 2019-20
1624833 292639 1773827 397158 1975769 515655 2273333 422085

The world's largest importers of methanol in 2019:
• China - 27% of the world imports ($2.9 billion)

• Netherlands - 7.61% ($796 million)
• USA - 7.36% ($770 million)
• India - 6.04% ($632 million)
• Japan - 4.89% ($512 million
The world's largest exporters of methanol in 2019:

• Saudi Arabia - 24% of the world exports ($1.2 billion)
• USA - 17% ($850 million)
• Netherlands - 13.4% ($674 million)
• Russia - 10.3% ($518 million)
• Malaysia - 9.02% ($451 million)
• Chile - 5.24% ($262 million)
Export Destinations of Methanol during 2019-20 QTY in MT & VAL in Rs. Lakh
Table 7.5: Export Destinations of Methanol
COUNTRY QUANTITY VALUE
NEPAL 3631.514 1039.216
KENYA 1427.337 427.273
NIGERIA 1182.020 322.551
TANZANIA REP 839.987 247.391
Product Total 11454.993 2909.324
Import Destinations of Methanol during 2019-20 QTY in MT& VAL in Rs. Lakh

Table 7.6: Import Destinations of Methanol
COUNTRY QUANTITY VALUE
QATAR 197464 38160.878
UAE 100210 17168.345
Product Total 2253639.476 416817.294
BHEL successfully demonstrated a facility to create 0.25 TPD (thermal design power)
methanol from high ash Indian coal using a 1.2 TPD Fluidized bed gasifier. The methanol
purity of the crude methanol produced is between 98 and 99.5 per cent.
COVID impact
India's methanol demand is taking a hit from the nationwide closures to stem the coronavirus
pandemic, with little prospect of a quick recovery as the country faces severe ullage issues
and demand erosion from the downstream sectors. Asia-Pacific still continues to represent the
largest as well as the fastest-growing regional market for methanol worldwide. However, the
impact of the pandemic and a slowed-down economy through the region will indeed have an
impact. In 2019-20, India had an installed Methanol Production capacity of 2 MT per annum,
but due to covid, methanol production is only 0.176 MT.
The scope of the export has been increasing due to the increase in production.
7.3 Marketing set-up and Area of Consumption
Consumption of methanol can be divided into two categories:

1. Industry consumptions
2. Consumer consumptions
1. Industry consumptions: there are numerous applications of methanol in the industries,

some of which are mentioned below:
• Adhesives

• Base materials in acrylic plastic

• Chemical agent in pharmaceuticals and agrichemicals
• Fuel in factories and for electricity generation
• Formation of acetic acid and formaldehyde
• Intermediates
• Industry uses
• Gasoline additive (MTBE)
• Paint additives
Figure 7.4: Areas of Consumption of Methanol
More than 40 per cent of the world’s methanol is used in energy-related applications.
2. Customer consumption: Some places where consumers use methanol are as follows:
• Adhesives
• Agricultural products
• Fuels and related products [blending 20% DME (Dimethyl Ether, a derivative of
methanol) in LPG]
• Food
• Intermediate
• Inks, resins, and dyes

• Medicine's
• Paints and plywood
• Plastic
Consumption of methanol during 2014-15 to 2019-20 in Million Tonnes
Table 7.7: Consumption of methanol
Year Consumption
2014-15 1.801
2015-16 1.830
2016-17 1.801
2017-18 2.034
2018-19 2.247
2019-20 2.449
8. Site Selection and Plant layout
Before any detailed work is done on the design, the technical and economic factors of the
proposed process should be examined. The various reactions and physical processes involved
must be considered, along with the existing and potential market conditions for the particular
product. A preliminary survey of this type gives an indication of the probable success of the
project and also shows what additional information is necessary to make a complete
evaluation. Various factors are required to be considered while deciding the location of the
plant; based on those factors the final locations must be judged. Considerable care must be
exercised in selecting the plant site and many other different factors should be considered.
Primarily, the plant should be selected where the minimum cost of production and maximum
product distribution can be obtained. Also, other factors, such as room for expansion and safe
living conditions for plant operation as well as the surrounding environment, are also
important. A firm general consensus as to the plant location should be obtained before a
design project reaches the detailed estimate stage, and a firm location must be established

upon completion of the detailed-estimate design of the place. Following is a list of items that
should be considered for site selection:
1. Designation of site as heavy industrial development area
2. Other similar chemical plants existing in the area
3. Presence of infrastructure, such as roads, and services such as electricity, gas, water, etc.
4. Appropriate drainage, terrain, sub-surface, etc.
5. Suitable access for transportation of raw materials and chemicals, and for the construction
6. Proximity to major transportation networks
7. Availability of local workforce. Distance of plants from local communities.
8. Availability of domestic water and plant cooling water.
9. Environmental discharge regulations.
10. Proximity to raw materials supply and market for product chemical
11. Existence of services equipped to deal with a major industrial accident
12. Meteorological data
13. Proposed or possible government restrictions regarding industrial development or
discharge emissions
14. Space for expansion
15. Price of land
16. Public opinion
17. Possibility of earthquakes, subsidence, avalanches, etc.
18. Availability of government regional development grants or tax incentives, subsidies, etc.
Preliminary Study-
Bases on raw material supply, energy supply, market understanding minimising our study to
2-3 different geological areas.
Secondary Study-
Consideration of other facilities like transportation so that movement of final product as well
as raw material is easy therefore further reducing our target locations.
Tertiary Study-
Consideration of other metrics such as supply of skilled and unskilled employees, political

consideration and keeping in mind future prospects of possible expansion as well to finalise
the plant location.
Raw Material Availability-

Major raw materials required to set up our plant are Hydrogen and Carbon Dioxide.
Carbon dioxide is readily available in air so we need to identify places where the
concentration of carbon dioxide is.
Our studies indicate that we need to choose plant location in such a way that more plants are
located in nearby regions as carbon dioxide emission in such regions is higher comparatively
to other regions.
Also carbon dioxide could be imported so we need a place which is logistically well
maintained.
Hydrogen is currently produced from fossil fuels and studies indicate that coasts of Andhra
Pradesh are rich in fossil fuels but these are non-renewable resources and as per the Indian
Government we are moving towards green hydrogen revolution and many companies like
Reliance and others have already invested in different parts of India.
Reliance Industries- Jamnagar, Gujarat
GAIL- Madhya Pradesh
NTPC- Rann Of Kachh
So Considering future prospects with easy availability we are left with two choices Madhya
Pradesh and Gujarat.
Energy Availability-
Although currently India is dependent on new renewable resources for energy, the future plan
is to utilise renewable sources of energy for a better and green environment.
Coastal areas or open areas can provide a good source of wind energy and solar energy
compared to others.
According to an article-
GUJARAT, LOCATED ON THE WESTERN COAST OF INDIA, IS AN ECONOMIC
POWERHOUSE that contributed roughly 8% of India’s total gross domestic product (GDP)
between 2011/12 and 2018/19. It is one of the most industrially focussed states in India, with
three quarters of Gujarat’s state GDP coming from the industrial sector. IEEFA also identifies
Gujarat as one of the five leading Indian states for renewable energy in terms of both existing

generation capacity as well as future potential. There was 2 gigawatt (GW) of solar power
capacity, 6GW of wind power capacity and 0.5GW of biomass capacity operational as of
March 2019
Table 8.1: Gujarat Electricity Sector Composition
Climate Conditions-
Plant should be located in a decent temperature range area in cold climatic conditions as costs
may be increased in creating a plant layout and with excessive heat, we may need to
introduce air conditioning equipment which may further increase the cost of plant layout.
Transportation Facilities-
Water, railroads and highways are common means of transportation used by major industrial
concerns. The kind and quantity of products and raw materials determine the most suitable
type of transportation facilities. Careful attention should be given to local freight rates and
existing railroad lines. The proximity to railroad centres and the possibility of canal, river,
lake, or ocean transport must be considered. Motor trucking facilities are widely used and can
serve as a useful supplement to rail and water facilities. If possible, the plant site should have
access to all three types of transportation.
Gujarat emerges the states with both the raw material supply and connected with the
world and inside the country with a good mode of transport. Analysed market scenario
strongly suggests Gujarat to be a state where the industry must be set up.

Water Supply-
The process industries use large quantities of water for cooling, washing, steam generation
and as a raw material in process. Hence, the plant must be located where a dependable supply
of water is available. A large river or lake is preferable, although deep wells or artesian wells
may be satisfactory if the amount of water required is not too great. The level of the existing
water table can be checked by consulting the state geological survey and information on the
constancy of the water table and the year-round capacity of local rivers or lakes should be
obtained. If the water supply shows seasonal fluctuations, it may be desirable to construct a
reservoir or to drill several standby wells.
The state is self-sufficient in its needs for domestic and commercial water consumption. The
Sardar Sarovar project in Gujarat will enhance the area under irrigation. The project will use
the waters of the Narmada to fill the seasonal rivers in the state. Several check dams have
been built to harness the irrigation potential of the river, which helps in cash crop cultivation.
The state has undertaken extensive canal construction to supply water to the arid regions of
Kutch.
Labour Supply-
The type and supply of labour available in the vicinity of a proposed plant site must be
examined. Consideration should be given to prevailing pay scales, restrictions on number of
hours worked per week, competing industries that can cause dissatisfaction or high turnover
rates among the workers, and variations in the skill and productivity of the workers. The site
selected for the plant setup has:
Renowned academic and research institutions, like IIM, NIT etc in Gujarat have a large pool
of skilled workforce. Industrial Training Institute (ITIs) in Jamnagar, trains employees at
shop floor level.
TAXATION AND LEGAL RESTRICTIONS-

State and local tax rates on property income, unemployment insurance and similar items vary
from one location to another. Similarly, local regulations on zoning, building codes, nuisance

aspects, and transportation facilities can have a major influence on the final choice of a plant
site.
In fact, zoning difficulties and obtaining the many required permits can often be much more
important in terms of cost and time delays than many of the factors discussed in the preceding
sections.
Plant Location: Kutch, Gujarat
PLANT LAYOUT-
The management of equipment and facilities specified from process flow sheet considerations
is a necessary requirement for accurate preconstruction cost estimation or for future design
involving piping, structural and electrical facilities. Careful attention to the development of
plots and elevation plans will point out unusual plant requirements and therefore, give
reliable information about building and site costs required for precise pre - construction cost
accounting. Rational design must include arrangements such as processing areas, storage
areas and handling areas in efficient coordination and with regards to such factors are given
below.
1.New site development or addition to a previously developed site.
2. Future expansion
3.Economic distribution of services- water, process streams, power and gas. 4.Weather
condition
5. Safety consideration-possible hazards of fire, explosions and fumes
6. building code requirements
7.Waste disposal problems
8. Sensible use of floor and elevation space.
Some points to be considered in plant layout are,

1. Effluent plant is located at the end of the premises
2. The cost of construction can be minimised by adopting a layout that gives the
shortest run of connecting pipe between equipment, and the least amount of structural
steel work. However, this will not necessarily be the best arrangement for operation
and maintenance.

3. Administration buildings, canteens are located near the entrance of the industry
where they will not interfere with production, and it is convenient to contact the
people outside the industry.
4. Laboratory and workshops are placed in the position form where it is easy to
communicate with all other departments.
5. Location of services like power plant, cooling water, pump house, and switch house
are done such that their usage is not hindered, and they are easily accessible in case of
fire.
6. Pipelines laid are minimal and human safety is taken into account.
7. Storage layout: Storage facilities for raw materials and products may be located in
isolated areas or in adjoining areas. Hazardous materials become a decided menace to
life and should be isolated when stored. Storage tanks must be separated to facilitate
suitable quantities. Process water may be drawn from rivers, wells or purchased from
local authorities. Electrical power will be needed at all sites. So, the plant should be
located close to a cheap source of power. A competitively priced fuel must be
available for steam and power generation.
8. Effluent disposal: Effluent disposal should be according to the Indian standards. The
appropriate authorities must be consulted during the initial site survey to determine
the standards that must be met.
9. Local community considerations: The local community must be able to provide
adequate facilities for the plant personnel: schools, banks, housing, and recreational
cultural facilities etc. Also, the plant should be located so that the local community is
not harmed. The proposed plant must fit in with and be acceptable to the local
community.
10. Availability of suitable land: Sufficient suitable land be available for the proposed
plant and for future expansion. The land should be ideally flat, well drained and have
suitable load bearing capacity. A full site evaluation should be made to determine the
need for pining or other special foundations. It should also be available at low cost.
11. Political and strategic consideration: Capital grants, tax concessions and other
incentives provided by governments to direct new investment to preferred locations,
such as areas of high unemployment should be the overriding considerations in the
site selection.

12. Exchangers-exchangers usually have standard length tubes of 2.5, 4, 5, and 6 metres.
Whenever possible, locate the exchanger at grade to facilitate maintenance and tube
withdrawal. Two or more shells forming one unit will be stacked, or otherwise
arranged as indicated on the exchanger specification sheet. Exchangers on dissimilar
service may be stacked never more than three high, except for fin tube units.
Horizontal clearance of at least 900 mm will be left between alternate exchangers,
providing sufficient space is left for maintenance and inspection access. Tube bundle
removal distance will be minimum tube length plus 900 mm. Minimum removal
distance plus 600 mm will be left behind the rear shell cover of floating head
exchangers. Where rear shell cover is provided with a davit, allow clearance for full
swing of the head. Set overhead vapour exchangers or condensers so that the
underside of the exchanger tube is self-draining. Arrange outlets to a liquid hold pot
or trap, so that the fixed end is at the channel end. Vertical exchangers should be set
to allow lifting or lowering of the tube bundle. Consult vessel section as to feasibility
of supporting vertical exchanger channel preferably pointing towards access areas or
roads. If the exchanger is situated well within the plot, leave a free area and approach
for mobile lifting equipment. Preferably air fin exchangers should be located in a
separate row outside the main equipment row, remote from the central pipe way.
Consider the location of air fin exchangers over the central pipe way if plot space is
very limited.
13. Pumps-Locate pumps close to the equipment from they take suction possibly under
structures or with motor ends under a pipe rack allowing an access aisle for mobile
handling equipment. Suction lines are generally larger than discharge lines, to avoid
problems arising from low NPSH. End suction, top discharge is preferable for pumps
taking suction directly from tanks or vessels located at grade. Pumps should be
arranged in rows with a centre line of discharges on a common line. Clearance
between pumps or pumps and piping shall be a minimum of 900 minimum.
Final Layout of Plant considering all the above points-

Figure 8.1: Plant Layout
9. Economic Evaluation & Profitability of the Project

Economic Evaluation & Profitability of the Project
The purpose of the economic analysis of the project is to bring about a better distribution of
resources, resulting in improved investment and spending revenue. Acceptable plant design
should introduce an economically efficient system that is able to operate under conditions
that will be able to show profit. Economic sustainability depends on the sustainability of
project outcomes. Project is sustainable if all its benefits or positive outcomes endure as
expected throughout the life project.
Since Net Profit is equal to the total income minus all costs, it is important that a Chemical
Engineer is aware of the many different types of costs involved in production processes.A
Capital Investment is required for any industrial process and decision-making required
investment is an important part of a crop design project. The total investment for any process
contains Fixed Capital Investment for portable tools and resources in the industry plus

operating costs that should be available to pay salaries, keep goods and services in hand and
carry some special items that require specific funds.
An economic assessment of the first proposed plant project will provide compelling reasons
to improve design. Before investors agree to spend a lot of money funding for the proposed
project, management must ensure that the project will provide sound investment. So the
economic process is just as important as the design process itself. Net payback period, Total
future value, Total current value and rate of return on investment will be considered in detail.
Based on these indications as to whether the proposed design will be evaluated.
Cost Estimations-
The primary goal of the methanol production plant is to make profit, and an estimate of the
investment required is needed earlier than the profitability of this mission may be evaluated.
Value estimation could start with the estimation of the capital costs. This will then be
accompanied by using running price estimates and finally based on those ; the profitability
signs of the design challenge are anticipated.
Capital Cost Estimates-

Two primary components in capital cost estimation are-
1. Fixed Capital
2. Working Capital
Fixed Capital-
Fixed capital consists of assets that are not consumed or destroyed in the production of a
good or service and can be used multiple times. Property, plant, and equipment are standard
fixed capital items. In Our case it can be defined as the total cost of designing, constructing,
and installing a plant and the associated modifications needed to prepare the plant site.
In simple terms it can be defined as the sum of Direct and Indirect Cost
Direct Costs:
1. Purchased equipment: Columns, Heat Exchangers, pumps, tanks, etc.
2. Equipment Installation
3. Piping (includes insulation)
4. Instruments and Control
5. Electrical Equipment.
6. Buildings: Process, Administration, Maintenance shops, etc.
7. Site Preparation
8. Service Facilities: steam, water, air, fuel, etc. Waste treatment, fire control, offices, etc.
9. Land
Indirect Costs:
1. Engineering and Supervision: Administrative and Design. Supervision and Inspection.
2. Construction Expenses
3. Contractor's fee
4. Contingency.
5. Start-up expenses
Working Capital-
Working capital represents short-term assets available to a business for meeting financial
obligations such as payroll, creditors, and suppliers. A company with insufficient working

capital can have liquidity problems even when their asset position and profitability is healthy.
In simple terms it can be defined as-
𝑾𝒐𝒓𝒌𝒊𝒏𝒈⁡𝑪𝒂𝒑𝒊𝒕𝒂𝒍⁡ = ⁡𝑹𝒆𝒄𝒆𝒊𝒗𝒂𝒃𝒍𝒆𝒔⁡ + ⁡𝑰𝒏𝒗𝒆𝒏𝒕𝒐𝒓𝒚⁡– ⁡𝑷𝒂𝒚𝒂𝒃𝒍𝒆𝒔⁡ + ⁡𝑪𝒂𝒔𝒉⁡𝒐𝒏⁡𝒉𝒂𝒏𝒅
Step-1
Purchases Equipment Cost-
Purchased equipment costs are helpful during a project's early development and budgeting.
The actual cost of a piece of equipment depends upon many factors. References for
evaluating equipment cost:
1. Coulson and Richardson’s, Volume 6, 4th Edition
2. Matches process Equipment Cost Estimates.
3. CAPCOST Software-CAPCOST software calculates the total cost of equipment based
upon its specifications such as wall thickness, diameter, length, operating pressure, etc Some
important considerations
1. The base year taken is 2014.
2. All the equipment are scaled to the present worth using the ‘Chemical Engineering Plant
Cost Index’ published regularly in the Chemical Engineering Magazine using the formula-
𝑃𝒓𝒆𝒔𝒆𝒏𝒕 𝑪𝒐𝒔𝒕 = 𝑶𝒓𝒊𝒈𝒊𝒏𝒂𝒍 𝑪𝒐𝒔𝒕( 𝒊𝒏𝒅𝒆𝒙 𝒗𝒂𝒍𝒖𝒆 𝒂𝒕 𝒑𝒓𝒆𝒔𝒆𝒏𝒕 𝒕𝒊𝒎𝒆 𝒊𝒏𝒅𝒆𝒙 /𝒗𝒂𝒍𝒖𝒆 𝒂𝒕
𝒕𝒉𝒆 𝒕𝒊𝒎𝒆 𝒐𝒓𝒊𝒈𝒊𝒏𝒂𝒍 𝒄𝒐𝒔𝒕 𝒘𝒂𝒔 𝒐𝒃𝒕𝒂𝒊𝒏𝒆𝒅)
Table 9.1 Cost Index
Year Index
Jan 2002 390.4
2021 776.9
Table 9.2 Equipment Cost
Equipment Name Price In INR (2021) Price In INR (2002)
Compressor (3) 8897861 4471264
Valve 393015 197494
Heat Exchanger (3) 807163 405607
Condenser 1266466 636412
Heater H1 2667533 1340462
Reactor R1 2285720 1967936
Flash Drum (2) 7088562 3562074
Distillation Column D1 1266466 636412
Total Cost of Purchased Equipment is 51171396

Step-2
Other Direct Costs-
1. Instruments and Controls- Include Components like safety valves, pressure control,
temperature control etc.
2. Piping- Pipes used in plants like GI, MS etc. and their fitting material for insulation
3. Utilities and Facilities- Utilities like compressor, generator, boiler etc are covered in
this section.
4. Non-Process Equipment- these are essential for company work purposes like fire
extinguishers.
5. Electrical Equipment- switches, motors, wires, fittings etc.
6. Construction of Building-
1. Process buildings
2. Auxiliary buildings
3. Maintenance shops
4. Building Services -Plumbing work (labour charges), Air Handling Units (HVAC),
Paint Material Labour charges for painting
1. Site Development- It includes following factors-

1. Site Clearing
2. Roads
3. Walkways
4. Landscaping
Table 9.3 Direct Costs
Item Percent of Purchased Cost Cost In INR
Purchased Equipment Cost 100 51171396
Purchased Equipment Installation 45 23027128.2
Instruments and Controls 13 6652281.48
Piping 30 15351418.8
Electrical Equipment 15 7675709.4
Building 30 15351418.8
Yard Improvements 10 5117139.6
Service Facilities 35 17909988.6
Land 40000000
Civil Architecture 20 10234279.2
Total Direct Cost 192490760

Step-2 B.
Other Indirect Costs-
Table 9.4 Indirect Costs
Item Percent Of Purchased Cost Cost In INR
Engineering and Supervision 32 33521132
Construction Expenses 34 35616203
Contractor’s Fee 18 18855637
Contingency 36 37711274
Legal Expenses 4 4190141
Total Indirect Cost 129894388
Step-2 C.
Total Capital Investment-
Table 9.5 Total Capital Investment
Description Cost In INR
Total Indirect Cost(I) 129894388
Total Direct Cost(D) 192490760
Fixed Capital(D+I) 322385148
Working Capital (20% of FC) 64477029
Start-Up Cost (10% of FC) 32238514
Total Capital Investment 741485840
Step-3
Total Product Cost-
Another equally important part is the estimation of costs for operating the plant and selling
the products. These costs can be grouped under the general heading of Total Product Cost A
tabular form is very useful for estimating total product cost and constitutes a valuable
checklist to preclude omissions
Basis for calculating total product cost is:

1. The Total Product Cost is calculated based on the Annual Cost Basis.
2. Number of days working per year is 300 days.
3. Plant is running in 3-shifts i.e., 24hrs per day.
4. Capacity of the plant per year is 30000 MTPA

Step-3 A.
Cost of Raw Material-
Cost of H2
Cost of CO2
Table 9.6 Raw Material Cost
Raw Consumption Coefficient (Per Rate (Per MT) Cost (Per MT) of
Material MT of Output) in INR Output
H2(green) 1 340000 340000
CO2 0.33 30000 9900
Total Cost = 89500000

Total Cost = (𝑹𝒂𝒘⁡𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍⁡𝑪𝒐𝒔𝒕⁡𝑷𝒆𝒓⁡𝑴𝑻) ⁡ ∗ 𝟑𝟎𝟎𝟎𝟎
Step-3 B.
Cost of Power and Utilities-
Table 9.7 Utilities
Utility Consumption Coefficient (Per MT Unit Rate In Cost (per MT of

of Output) INR Output)
Steam 4.5 1300 5850
Power 1200 5.75 6900
Water 0.11 30 3.3
Water 2000
Disposal
Utility Cost Per MT Methanol = 14753
Step-3 C.
Total Annual Direct Production Cost
Table 9.8 Production Cost
Description Cost In INR
Raw Materials 89500000
Utilities 202511803

Operating Labour 60400000
Operating Supervision 12320000
Maintenance and Supervision 4926900
Operating Supplies 4728560
Laboratory Charges 6046690
Total 380433953
Step-3 D.
Fixed Charges
Fixed Assets will undergo Depreciation during their life cycle
Average Annual Depreciation = 𝐹𝑖𝑥𝑒𝑑⁡𝐶𝑎𝑝𝑖𝑡𝑎𝑙⁡𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡/𝐸𝑥𝑝𝑒𝑐𝑡𝑒𝑑⁡𝐿𝑖𝑓𝑒
Where expected life is 20 yrs.

Average Annual Depreciation = 16119257
Table 9.9 Fixed Charges
Nature of Expenditure Cost In INR
Depreciation 16119257
Local Taxes (1% of FC) 3223851
Insurance (1% of FC) 3223851
Total Fixed Charges = 22566959
Overhead cost is assumed as 30% of the cost of operating labour, supervision, and
maintenance.
Plant Overhead Cost= 23294070
Step-3 E.
Total Manufacturing Cost (M)
Table 9.10 Total Manufacturing Cost
Description Total Annual Cost in INR
Direct Production Cost 380433953
Fixed Charges 45990347

Plant Overhead Cost 23294070
Total 449718370
Step-3 F.
General Expenses
Table 9.11 General Expenses
Nature of Expenses Cost in INR
Administrative Costs 11400000
Distribution And Marketing Costs 124119212
Research and Development (3% of Production Cost) 11413018
Total 249532230
Step-3 G.
Total Product Costs (TPC)
𝑇𝑜𝑡𝑎𝑙⁡𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔⁡𝐶𝑜𝑠𝑡(𝑀) ⁡
= ⁡𝐷𝑖𝑟𝑒𝑐𝑡⁡𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛⁡𝐶𝑜𝑠𝑡⁡ + ⁡𝐹𝑖𝑥𝑒𝑑⁡𝐶ℎ𝑎𝑟𝑔𝑒𝑠⁡ + ⁡𝑃𝑙𝑎𝑛𝑡⁡𝑂𝑣𝑒𝑟ℎ𝑒𝑎𝑑⁡𝐶𝑜𝑠𝑡
TPC = 𝑻𝒐𝒕𝒂𝒍⁡𝑴𝒂𝒏𝒖𝒇𝒂𝒄𝒕𝒖𝒓𝒊𝒏𝒈⁡𝑪𝒐𝒔𝒕⁡ + ⁡𝑻𝒐𝒕𝒂𝒍⁡𝑮𝒆𝒏𝒆𝒓𝒂𝒍⁡𝑬𝒙𝒑𝒆𝒏𝒔𝒆𝒔 = 699250600
Step-4
Profitability Analysis-
Annual Revenue Through Sales = 𝑃𝑒𝑟𝑐𝑒𝑛𝑡⁡𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 ∗ ⁡𝑀𝑎𝑟𝑘𝑒𝑡⁡𝑉𝑎𝑙𝑢𝑒
Gross Profit = 𝐴𝑛𝑛𝑢𝑎𝑙⁡𝑟𝑒𝑣𝑒𝑛𝑢𝑒⁡𝑇ℎ𝑟𝑜𝑢𝑔ℎ⁡𝑆𝑎𝑙𝑒𝑠⁡ − ⁡𝑇𝑜𝑡𝑎𝑙⁡𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔⁡𝐶𝑜𝑠𝑡
Net Profit = 𝐺𝑟𝑜𝑠𝑠⁡𝑃𝑟𝑜𝑓𝑖𝑡⁡(1 − ⁡𝑡𝑎𝑥⁡𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒/100)

𝑇𝑜𝑡𝑎𝑙⁡𝐹𝑖𝑥𝑒𝑑⁡𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
Payback Period = (𝑁𝑒𝑡⁡𝑃𝑟𝑜𝑓𝑖𝑡⁡+⁡𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛)⁡
(𝑁𝑒𝑡⁡𝑃𝑟𝑜𝑓𝑖𝑡⁡∗⁡100)
Rate of Return = 𝑇𝑜𝑡𝑎𝑙⁡𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
Table 9.12 Profitability Analysis
Market value of Finished Products (Rs/Kg) 40 INR
Annual revenue Through Sales 1200000000 INR

Gross Profit 500749400 INR
Assuming Tax Percent 45
Net Profit 275412170 INR
Payback Period 1.10 Years
Rate of Return 39.3 %
Breakeven Analysis-
Let the plant operate at ‘x’ fraction of its capacity which is its Break-Even Point (BEP) of Zero
profit
Revenue at BEP = 1200000000 ∗ 𝑥

Total fixed costs = 𝑓𝑖𝑥𝑒𝑑⁡𝑐𝑜𝑠𝑡⁡ + ⁡𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑⁡ + ⁡𝑔𝑒𝑛𝑒𝑟𝑎𝑙⁡𝑒𝑥𝑝𝑒𝑛𝑠𝑒𝑠
= 322385148 + 23294070 + 249532230
= 595211448
Total direct costs = 380433953
Direct Cost at BEP = 380433953 ∗ 𝑥
At BEP
1200000000 ∗ 𝑥⁡ = ⁡380433953 ∗ 𝑥⁡ + ⁡595211448
x= 0.72625
i.e., at 72.6% capacity of the plant we will break even
Cash Flow Chart

Assuming minimum rate of 6%

Table 9.13 Cashflow Chart
Cumulative Cash Flow-

Present Worth
Year Net Profit/yr Depreciation Cash Flow Present Value Total Cost of
Factor
Investment
1 275412170 16119257 291531427 0.94 274039541.4 -48345606.62
2 275412170 16119257 291531427 0.8836 257597168.9 209251562.3
3 275412170 16119257 291531427 0.830584 242141338.8 451392901
4 275412170 16119257 291531427 0.78074896 227612858.4 679005759.5
5 275412170 16119257 291531427 0.733904022 213956086.9 892961846.4
6 275412170 16119257 291531427 0.689869781 201118721.7 1094080568
7 275412170 16119257 291531427 0.648477594 189051598.4 1283132167
8 275412170 16119257 291531427 0.609568939 177708502.5 1460840669
9 275412170 16119257 291531427 0.572994802 167045992.4 1627886661
10 275412170 16119257 291531427 0.538615114 157023232.8 1784909894
11 275412170 16119257 291531427 0.506298207 147601838.8 1932511733
12 275412170 16119257 291531427 0.475920315 138745728.5 2071257462
13 275412170 16119257 291531427 0.447365096 130420984.8 2201678446
14 275412170 16119257 291531427 0.42052319 122595725.7 2324274172
15 275412170 16119257 291531427 0.395291799 115239982.2 2439514154
16 275412170 16119257 291531427 0.371574291 108325583.2 2547839738
17 275412170 16119257 291531427 0.349279833 101826048.2 2649665786
18 275412170 16119257 291531427 0.328323043 95716485.35 2745382271
19 275412170 16119257 291531427 0.308623661 89973496.23 2835355767
20 275412170 16119257 291531427 0.290106241 84575086.46 2919930854
In the second year cost invested is recovered.
(CCF-TCI) vs Years
3.5E+09
3E+09
2.5E+09
2E+09
1.5E+09
1E+09
500000000
0
0 5 10 15 20 25
-5E+08
Figure 9.1 (CCF-TCI) vs Years

10. References
1. https://www.mayoclinic.org/diseases-conditions/carbon-monoxide/symptoms-
causes/syc-20370642 [15-04-2022]
2. https://www.nhlbi.nih.gov/health-topics/respiratory-failure [15-04-2022]
3. https://www.cpilink.com/blog/air-pollution-control-technology-review-biological [15-
04-2022]
4. https://www.cpilink.com/blog/air-pollution-control-technology-review-condensation
[15-04-2022]
5. https://www.cecoenviro.com/scrubbers. [15-04-2022]
6. Pollution Control Equipment [15-04-2022]
7. https://www.epa.gov/hw/criteria-definition-solid-waste-and-solid-and-hazardous-
waste-exclusions [15-04-2022]
8. https://www.eib.org/attachments/pipeline/1294_EIA_en.pdf [15-04-2022]
9. Hazardous Effects of Petrochemical Industries: A Review- Juniper Publishers [15-04-
2022]
10. Worley Parsons Komex – https://www.eib.org/attachments/pipeline/1294_EIA_en.pdf
[15-04-2022]
11. Effect of ternary blends on the noise, vibration, and emission characteristics of an
automotive spark ignition engine [15-04-2022]
12. Efficient methanol synthesis: Perspectives, technologies, and optimization strategies
[15-04-2022]
13. https://www.mdpi.com/1996-1073/12/19/3742/pdf [15-04-2022]
14. Pollution characterization of liquid waste of the factory complex Fertial (Arzew,
Algeria) [15-04-2022]
15. https://www.conserve-energy-future.com/sources-and-causes-of-water-pollution.php
[15-04-2022]
16. https://www.nrdc.org/stories/water-pollution-everything-you-need-know [15-04-
2022]
17. https://www.researchgate.net/figure/Top-CRIs-George-Olah-Renewable-Methanol-
plant-in-Svartsengi-Iceland-Bottom-Block_fig1_327908984 [04-02-2022]
18. https://smartech.gatech.edu/handle/1853/61845 [25-01-2022]
19. Gujarat: Where Business is a way of Life | IBEF [07-02-2022]

20. Five Indian companies leading the green hydrogen revolution (livemint.com) [28-01-
2022]
21. Gujarat-Electricity-Sector-Transformation_Final_August-2019.pdf (ieefa.org) [03-02-
2022]
22. http://ddbonline.ddbst.com/AntoineCalculation/AntoineCalculationCGI.exe [06-04-
2022]
23. https://onlinelibrary.wiley.com/doi/pdf/10.1002/9781118135341.app1 [06-04-2022]
24. http://kth.diva-portal.org/smash/get/diva2:1290829/FULLTEXT01.pdf [13-04-2022]
25. https://www.toweringskills.com/financial-analysis/cost-indices/ [13-04-2022]
26. http://www.mhhe.com/engcs/chemical/peters/data/ [14-04-2022]



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30000 MTPA Production of Methanol using H2/CO2 as

requirements for the award of the degree

(Enrolment No. 18118018)

DEPARTMENT OF CHEMICAL ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 1|Page

Place: Roorkee (Dr. Taraknath Das)

Dated: April 16, 2022 Assistant Professor

Department of Chemical Engineering

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 2|Page

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 3|Page

Enrollment No. 18118018

Department of Chemical Engineering

Indian Institute of Technology Roorkee

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 4|Page

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 5|Page

2.1 Process Summary ........................................................................................................... 10

3.1 Introduction .................................................................................................................... 12

3.2.2.2 Techno-economic appraisal of alternative processes/schemes ........................ 21

3.2.2.3 Status of technologies/schemes available ........................................................ 22

3.2.2.4 Selection of technology/schemes ..................................................................... 23

3.2.2.5 Source of knowhow of selected process/technology ....................................... 24

3.2.3 Raw Materials .......................................................................................................... 25

3.2.3.2 Requirement of raw materials .......................................................................... 29

3.2.3.3 Availability: Indigenous/Imported ................................................................... 29

3.2.3.4 Government policies for import of raw material ............................................. 32

3.2.3.5 Prevailing Prices .............................................................................................. 34

3.2.3.6 Testing procedures for the raw materials: ........................................................ 34

3.3 Material and Energy Flow Information .......................................................................... 34

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 6|Page

3.4.5 Major engineering problems and their remedies ..................................................... 88

4.1 Environmental Aspect .................................................................................................. 121

5.1 Air System .................................................................................................................... 140

6.1 Organizational Structure .............................................................................................. 148

7.1 Brief Analysis of Demand and Supply Of methanol.................................................... 156

9. Economic Evaluation & Profitability of the Project ......................................................... 172

10. References .................................................................................................................. 182

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DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 9|Page

2.2 Organizational Structure

Figure 2.1 Organizational Chart

Total skilled employees: 80

Total unskilled employees: 100

Total organization cost per month: ₹ 95 lakhs (approximately).

Total organization cost per annum: ₹ 11.4 crores (approximately)

DEPARTMENT OF CHEMICAL ENGINEERING, IIT ROORKEE 10 | P a g e

2.3 Utility Usage

Utility Consumption Coefficient (Per MT Unit Rate In Cost (per MT of

Steam 4.5 1300 5850

Power 1200 5.75 6900

Water 0.11 30 3.3

2.4 Cost and Profit Information

Total Fixed Capital 322385148 INR

Total Working Capital 64477029 INR

Total Manufacturing Cost 449718370 INR

Market value of Finished Products (Rs/Kg) 40 INR

Annual revenue Through Sales 1200000000 INR

Gross Profit 500749400 INR

Assuming Tax Percent 45